BEDIENUNGSANLEITUNG2005

Transcription

1 BEDIENUNGSANLEITUNG LC4 ENDURO 640 LC4 SUPERMOTO OWNER`S MANUAL MANUALE D`USO MANUEL D`UTILISATION MANUAL DE INSTRUCCIONES ART. NR

2 IMPORTANT» Please read this manual carefully and completely before going on your first ride. It contains a great deal of information and advice which will help you use and handle your bike properly. In your own interest, please pay particular attention to notices that are marked as follows: IGNORING THESE INSTRUCTIONS CAN BE DANGEROUS TO LIFE AND LIMB! IGNORING THESE INSTRUCTIONS MAY DAMAGE PARTS OF THE MOTORCYCLE OR IMPAIR THE MOTOR- CYCLE S TRAFFIC SAFETY! Please insert the serial numbers of your motorcycle in the boxes below Frame number Engine number Key number Stamp of dealer COMSUMER INFORMATION FOR AUSTRALIA ONLY Tampering with noise control system prohibited Owners are warned that the law may prohibit: (a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; and (b) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations, descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models. 004 by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTM-SPORTMOTORCYCLE AG, Mattighofen only.

3 INTRODUCTION» We would like to congratulate you on your purchase of a KTM motorcycle. You are now the owner of a state-of-the-art sport motorcycle that guarantees to ing you lots of fun and enjoyment, provided that you clean and maintain it appropriately. Before you go for your first ride, be sure to read this manual carefully and thoroughly in order to familiarize yourself with how to operate your new motorcycle and with its characteristics, even if this means that you will have to dedicate some of your valuable time to this task. Only by doing so will you learn how to tune your motorcycle to your specific needs and how to protect yourself against injury. Besides, this manual contains important information on motorcycle maintenance. At the time this manual was typeset, it was up-to-date with the latest state of this production series. It cannot be completely ruled out, however, that minor discrepancies may exist resulting from further design upgrades of these motorcycles.this manual is an important part of your motorcycle and should be passed on to any subsequent owner in case you decide to sell it. We expressly point out that work marked with an asterisk in the chapter "Maintenance work on the chassis and engine" must be performed. If maintenance work should become necessary during a competition it should be performed by a trained mechanic. KTM strongly recommends that all service work to your KTM should be performed by a qualified KTM dealer. For your own safety, use KTM-approved parts and accessories only. KTM is not liable for damage that arises in connection with the use of other products. Take special care to follow the recommended run in, inspection, and maintenance intervals. Heeding these guidelines will significantly increase the life of your motorcycle. To ensure that all work to your KTM is performed properly and to avoid warranty conflicts, KTM recommends that you always have your KTM serviced by a recognized and qualified KTM dealer. Off-road motorcycle driving is a wonderful sport and we hope that you will be able to enjoy it to the full. It may, however, involve potential problems for the environment or lead to conflicts with others. These problems or conflicts can be avoided if the motorcycle is used responsibly. To safeguard the future of motorcycle sports, make sure that you use the motorcycle in accordance with the law, show that you are environmentally conscious and respect the rights of others. We wish you a lot of fun when driving! KTM-SPORTMOTORCYCLE AG 530 MATTIGHOFEN, AUSTRIA Attachments: spare parts manual chassis & engine

4 IMPORTANT LIMITED WARRANTY AND LIMITED GUARANTEE INFORMATION» The 640 LC4 Enduro model was designed to resist the usual wear and tear of normal use on the road and easy terrain (unpaved roads). The 640 LC4 Supermoto model is designed for regular on-road service but not for use off of paved roads. The service, care and operating instructions for the engine and chassis specified in the owner's manual must be observed to ensure that the bike runs smoothly and to avoid premature wear. The service work specified in the "Luication and Maintenance Schedule" must be performed and service records must be kept for warranty documentation. Lack of proper service and maintenance records or documentation could void warranty. The fuels and luicants specified in the owner's manual or those of an equal quality must be used in accordance with the maintenance schedule. The warranty or guarantee shall become void for damage and consequential damage caused by manipulations or conversions to the motorcycle. The use of the motorcycle under extreme conditions, e.g. on extremely muddy and wet terrain, can lead to higher than average wear on components such as the drive train or the akes. In this case it may become necessary to service or replace wear parts before the service limit specified in the maintenance schedule has been reached. 3 No warranty will be assumed if the bike is used in races or competitions. In accordance with the international quality management ISO 900 standard, KTM uses quality assurance processes that lead to the highest possible product quality.

5 INDEX» 4 Page SERIAL NUMBER LOCATIONS Chassis number Engine number, engine type OPERATION INSTRUMENTS Clutch lever Hand decompression lever Hand ake lever Choke lever Ignition lock with 3 switch positions Multi-functional digital speedometer Display Setting options in the display Cooling liquid temperature display Indicator lamps Combination switch Starter tip switch, emergency OFF tip switch, light switch.0 Filler cap Fuel tap Shift lever Kickstarter Foot ake pedal Compression damping of fork Rebound damping of fork Compression damping of shock absorber Rebound damping of shock absorber Holding bars (LC4 Enduro) Grip (LC4 Supermoto) GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE Instructions for initial operation Running in the LC4 models Accessories and payload DRIVING INSTRUCTIONS Check the following before each start Starting when the engine is cold Starting when the engine is warm or hot What to do when the engine is flooded Kickstart instructions Starting off Shifting/Riding Braking Stopping and parking Fuel PERIODIC MAINTENANCE SCHEDULE Page Adjusting of free travel at the hand ake lever (LC4 Enduro).7 Changing the basic position of the handake lever (LC4 Supermoto) Checking of ake fluid level - front ake Refilling the front ake fluid reservoir Checking the front ake pads (LC4 Enduro) Checking the front ake pads (LC4 Supermoto) Changing the basic position of the foot ake pedal..8 Checking rear ake fluid level Checking the rear ake pads Dismounting and mounting the front wheel (LC4 Enduro).30 Dismounting and mounting the front wheel (LC4 Supermoto) Dismounting and mounting the rear wheel Checking the shock absorption rubbers in the rear hub.3 Tires, air pressure Checking spoke tension Changing the wheel size Battery Charging the battery Fuses Exchanging the ake light and tail light bulb (LC4 Enduro) Exchanging the ake light and tail light bulb (LC4 Supermoto) Exchanging the headlight lamp (LC4 Enduro) Replacing the parking-light bulb (LC4 Enduro) Exchanging the headlight lamp (LC4 Supermoto) Replacing the parking-light bulb (LC4 Supermoto)...36 Cooling system Checking the cooling liquid level Cleaning the air filter (LC4 Enduro) Cleaning of air filter (LC4 Supermoto) Exhaust system (LC4 Supermoto) Changing the original position of the clutch lever Checking the oil level of the hydraulic clutch Checking and adjusting the choke play Checking the adjustment of the hand decompression Adjust the throttle Activating the ignition curve for low-octane fuel Adjust idling speed Draining the carburetor float chamber Engine oil Checking the engine oil level Oil circuit Oil and screen filter change, bleeding of the oil system.43 Changing oil filter MAINTENANCE WORK ON CHASSIS AND ENGINE....0 Tool set (LC4 Enduro) Removing the seat (LC4 Enduro) Removal of seat (LC4 Supermoto) Tool set (LC4 Supermoto) Checking and adjusting steering head bearing Bleeder screws for telescopic fork Cleaning the dust sleeves of the telescopic fork..... Changing the spring preload of the shock absorber...3 Luicating the shock absorber linkage Checking rubber ring on the WP rear shock absorber..3 Checking chain tension Correct chain tension Chain maintenance Chain wear General informations about KTM disc akes TROUBLE SHOOTING CLEANING CONSERVATION FOR WINTER OPERATION STORAGE Re-initiation after time of storage TECHNICAL SPECIFICATIONS - CHASSIS TECHNICAL DATA ENGINE HEAD WORD INDEX WIRING DIAGRAM appendix

6 SERIAL NUMBER LOCATIONS» Chassis number The chassis number is stamped on the right side of the steering head tube. Write this number into the relevant area on page. Engine number, engine type The engine number and engine type are stamped on the right hand side of the engine below the chain sprocket. Write this number into the relevant area on page. 5

7 OPERATION INSTRUMENTS» A Clutch lever The clutch lever [] is located on the left side of the handlebar. The adjusting screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically. Hand decompression lever The hand decompression lever [] is only used in two special cases: a) When the engine stalled. It is possible that the starter motor is not able to crank the engine on the next attempt. This is due to the fact that the automatic decompressor doesn t work properly. If this happens, pull the manual decompression lever and start again. Afterwards normal starting will be possible. b) When you want to push the motorcycle. While pushing, pull the hand decompression lever to make it easier to get the engine going. 6 Hand ake lever The hand ake lever [3] is mounted on the handlebars on the right and actuates the front wheel ake. The adjusting screw [B] can be used to change the basic position of the hand ake lever (see "Maintenance"). B 3 4 Choke lever If the choke lever [4] is pulled backwards, a bore will be opened in the carburetor through which the engine may draw in additional fuel. This produces a rich fuel/air mixture necessary for cold start. If the choke lever is pushed forward up to the stop, the bore will be closed again. In this position the choke must have a play of approx. 4 mm. 5 Ignition lock with 3 switch positions Switch positions of ignition lock [5]: = Ignition off, (engine can't be started) = Ignition on, (engine can be started) = Ignition off, handlebar blocked To switch the ignition to position turn the ignition key to position and firmly press it into the lock. Turn the handlebar all the way to the left, then turn the ignition key to the left. The ignition key can be withdrawn in position and.

8 OPERATION INSTRUMENTS» 3 Multi-functional digital speedometer The universal instrument is divided into 3 parts. Use the MODE and SET [] button to change the display and the basic settings in the display. Display [] shows all of the information that may be of interest to you. 5 display modes can be selected with the MODE button. The indicator lamps [3] provide additional information on the motorcycle's running condition. TEST Display TEST When you switch on the ignition, all of the display elements will light up for second for the function test. WS WS (wheel size) The display will change and show the diameter of the front wheel in inches for second (WS = wheel size). Then the CLOCK mode will be displad, or the mode that was active when the ignition was switched off. 7 CLOCK CLOCK You will recognize the OK display by the blinking dots between the hours and minutes. It displays the speed, temperature of the cooling liquid and the clock. To switch to the next display mode, press the MODE button. ODO ODO The speed, temperature of the cooling liquid and the total kilometers or miles traveled are shown in the ODO mode. To switch to the next display mode, press the MODE button. TRIP TRIP The TRIP mode shows the speed, the temperature of the cooling liquid and the trip odometer. To switch to the next display mode, press the MODE button. TRIP TRIP The TRIP mode shows the speed, the temperature of the cooling liquid and the trip odometer. To switch to the next display mode, press the MODE button. TRIP F TRIP F The TRIP F (fuel) mode shows the speed, the temperature of the cooling liquid and the distance traveled since reaching the low-fuel mark (the low-fuel indicator lamp will blink). To return to the UHR mode, press the MODE button.

9 OPERATION INSTRUMENTS» 0 sec Setting options in the display KILOMETERS OR MILES. You can have the speed and distance shown in kilometers or miles in the display. The display can be adapted to the respective country on long-distance trips. To switch from kilometers to miles, switch on the ignition and press the MODE [] button for approx. 0 seconds. The km/h display will switch to mph. The speed and the stored distances will be converted and displad in miles. To return to kilometers, proceed as described above. CLOCK Switch on the ignition and change to the CLOCK mode. Simultaneously press MODE [] and SET []. The numbers on the clock will start to blink. Use the MODE button to set the hours and the SET button to set the minutes. The press the MODE and SET buttons simultaneously. NOTE: 0:00 will be displad if the clock is not supplied with electricity. This can be caused by a defective fuse or a fault in the board electric system (see Troubleshooting). 8 TRIP The trip meter runs continuously and counts up to It can be used to measure the length of a certain route on a trip or the distance between two refueling stops. To return the trip meter to zero, switch on the ignition, change to the TRIP mode and press the SET button. RESETTING TRIP The trip meter runs continuously and counts up to It can be used similarly to TRIP or together with a switch available as an accessory (see below) for trips according to a roadbook. To return the trip meter to zero, switch on the ignition, change to the TRIP mode and press the SET button. NOTE: A Tripmaster switch (Part no ) is available as an accessory and enhances the trip meter functions. You can correct the displad route by increasing or decreasing in increments of 0.. For example, if you have taken the wrong road when driving according to a roadbook, you can easily correct the display to correspond to the roadbook again. It can also be used to change the display modes. The switch is mounted on the handlebars so that you can keep your hands on the handlebars.

10 OPERATION INSTRUMENTS» 0 C (48 F) 0 C (30 F) 00 C ( F) 70 C (58 F) 60 C (40 F) 50 C ( F) 40 C (04 F) Cooling liquid temperature display The temperature display [] is shown in 7 bars. The more bars that light up, the hotter the cooling liquid. When the lowest bar lights up, the cooling liquid has reached a temperature of approx. 40 C (04 F). When the upper bar lights up 0 C (48 F), all of the bars will start to blink and the red warning lamp [] will light up. POSSIBLE CAUSES FOR AN INCREASE IN TEMPERATURE, CAUSING THE RED WARNING LIGHT FOR THE COOLING LIQUID TEMPERATURE TO LIGHT UP: DRIVING TOO SLOWLY AND DRIVING WITH A HEAVY LOAD AT HIGH AIR TEM- PERATURES NOT ENOUGH COOLING LIQUID IN THE SYSTEM THE VENTILATOR ON THE RADIATOR IS NOT RUNNING IMPROPER USE OF THE CLUTCH WHEN DRIVING SLOWLY Indicator lamps The green indicator lamp will blink in the blinker rhythm when the blinker is switched on. NOTE: The indicator lamp will blink slower when a blinker is oken. The green indicator lamp will light up when the gearbox is in an idling position. The blue indicator lamp will light up when the high beams are switched on. 9 The red warning lamp will start to blink when the cooling liquid reaches 0 C (48 F). This warning light has no function. This warning light has no function. This indicator lamp has no function.

11 OPERATION INSTRUMENTS» Combination switch The rocker switch LIGHTS [] actuates the high beam or low beam. = High-beam light = Low-beam light The light signal (high beam) is actuated with button []. 3 The indicator switch [3] returns to central position after actuation. Press flasher switch towards switch housing to switch off the flasher. The horn is sounded with button [4] Starter tip switch, emergency OFF tip switch, light switch The emergency off switch [5] is provided for emergency situations and should not be used to switch off the engine. The engine is ready for operation in position (ignition circuit and starter circuit are switched on). The engine cannot be started in position (ignition circuit and starter circuit are interrupted). The light switch [6] has 3 positions: 7 = Light off = Parking light on = Headlight on Use the starter tip switch [7] to operate the electric starter. 8 Filler cap The filler cap [8] can be locked and is provided with a fuel evaporation control system. To open the cap insert the ignition key, turn it 90 counterclockwise, then lift off the filler cap. To close the tank insert the filler cap, turn the ignition key 90 clockwise and take out the key.

12 OPERATION INSTRUMENTS» Fuel tap OFF In this position the fuel tap is closed. No fuel may flow to the carburetor. ON RES When using the motorcycle, the twist grip must be set to the ON position. Now fuel may flow to carburetor. In this position the tank empties down to the fuel reserve of approx..5 liters. The reserve, approximately.5 liters, cannot be tapped until the twist grip is turned to the RES position. Fill the tank as soon as possible and remember to turn the twist grip back to the ON position so that you will have backup fuel next time, too. O FF OFF ON RES R E S NO FUE L O FF R E S NO FUE L O FF R E S NO FUE L,3,4,5 Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear. N Kickstarter The kickstarter is mounted on the left side of the engine. Its upper part can be swivelled. Foot ake pedal The foot ake pedal is located in front of the right footrest. Its basic position can be adjusted to your seat position (see maintenance work).

13 OPERATION INSTRUMENTS» Compression damping of fork The compression damping is to be set at the lower end of the fork tubes. It only regulates the degree of damping during compression. Remove closing cap [A]. By using the knob [] (COM), the degree of damping of the compression can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during compression. A BASIC SETTING: turn rotary knob clockwise as far as it will go turn it back counter-clockwise by as many clicks as are specified for the relevant type of fork WP 0587A0...0 clicks WP 487A clicks (640 LC4) (640 LC4 Supermoto) Rebound damping of fork The rebound damping is to be set at the upper end of the fork tubes. It only regulates the degree of damping during rebounding. By using the knob [] (REB), the degree of damping of the rebound can be adjusted. Turn the knob clockwise to increase damping, turn it counterclockwise to reduce damping during rebounding. BASIC SETTING: turn rotary knob clockwise as far as it will go turn it back counter-clockwise by as many clicks as are specified for the relevant type of fork WP 0587A0... clicks WP 487A clicks (640 LC4) (640 LC4 Supermoto) Compression damping of shock absorber With the knob [3] the degree of damping of the compression can be adjusted to 7 positions. Turn the knob counterclockwise to increase damping, turn it clockwise to reduce damping during compression. BASIC SETTING: 3 WP 087A03...position 3 WP 087A0...position 4 (640 LC4) (640 LC4 Supermoto) Rebound damping of shock absorber With the setting wheel [4] the degree of damping of the rebound can be adjusted to positions. Turn the knob to the left side to increase damping, turn it to the right side to reduce damping during rebounding. BASIC SETTING: 4 WP 087A03...position 7 WP 087A0...position 8 (640 LC4) (640 LC4 Supermoto) THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGHLY COM- PRESSED NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT. Holding bars (LC4 Enduro) The passenger can hold on to the holding bars on the rear end of the vehicle. Grip (LC4 Supermoto) The passenger grip is located in the center of the seat.

14 GENERAL TIPS AND WARNINGS FOR STARTING THE MOTORCYCLE» Instructions for initial operation Verify that your KTM dealer performed the PREPARATION OF VEHICLE jobs (see Customer Service Manual). Read these operating instructions carefully before your first ride. Enter the chassis, engine and key numbers on page. Familiarize yourself with the operating elements. Adjust the hand ake lever and foot ake lever to your most comfortable position. Get used to handling the motorcycle on an empty parking lot or open space, before starting on a longer drive. Also try to drive as slowly as possible and in standing position, to improve your feeling for the vehicle. Do not drive along off-road tracks which go beyond your abitily and experience. Hold the handlebars with both hands and leave your feet on the foot rests while driving. Remove your foot from the foot ake lever when you are not aking. If the foot ake lever is not released the ake pads rub continuously and the aking system is overheated. Do not make any alterations to the motorcycle and always use ORIGINAL KTM SPARE PARTS. Spare parts from other manufacturers can impair the safety of the motorcycle. Motorcycles are sensitive to changes in the weight distribution. Read the section on "Accessories and payload when carrying luggage. Pay attention to running-in procedure. Running in the LC4 models Even very precisely machined sections of engine components have rougher surfaces than components which have been sliding against one another for quite some time. Therefore, every engine needs to be oken in. For this reason, during its first 000 kilometers (60 miles) the engine must not be revved up to its performance limits. The engine speed of 4800 r.p.m. must not be exceeded during the first 000 kilometers (60 miles). During this eak-in time, you should ride your motorcycle in different conditions (roads, easy off-road terrain). The following table shows you the maximum velocity values in the different gears at 4800 r.p.m. as based on the rear wheel transmission ratio of your motorcycle. ratio LC4 Enduro LC4 Supermoto gear 6:4 Z 7:4 Z. G 35 km/h 35 km/h. G 50 km/h 55 km/h 3. G 70 km/h 75 km/h 4. G 90 km/h 90 km/h 5. G 00 km/h 00 km/h NOTE: During the stage of running the engine in, that is the first 000 KM (60 miles), the engine oil used should be of a mineral oil formula. This also applies if the engine has been repaired. WEAR SUITABLE CLOTHING WHEN DRIVING A MOTORCYCLE. CLEVER KTM DRIVERS ALWAYS WEAR A HELMET, BOOTS, GLOVES AND A JACKET, REGARDLESS OF WHETHER DRIVING ALL DAY OR JUST FOR A SHORT TRIP. THE PROTECTIVE CLOTHING SHOULD BE BRIGHTLY COLORED SO THAT OTHER VEHICLE CAN SEE YOU AS EARLY AS POSSIBLE. YOUR PASSENGER WILL ALSO NEED SUITABLE PROTECTIVE CLOTHING. DO NOT DRIVE AFTER HAVING CONSUMED ALCOHOL. ALWAYS TURN ON THE LIGHT TO MAKE SURE THAT OTHER DRIV- ERS BECOME AWARE OF YOU AS EARLY AS POSSIBLE. THE FRONT AND REAR WHEEL ARE ALLOWED TO BE FITTED ONLY WITH TIRES THAT HAVE THE SAME PROFILE TYPE. NEW WHEELS HAVE A SMOOTH SURFACE, WHICH MEANS THAT THEY MUST BE RUN IN TO ACHIEVE FULL GRIP. FOR THIS PUR- POSE, RIDE THE MOTORCYCLE CAREFULLY AT MODERATE SPEED DURING THE FIRST 00 KILOMETERS WITH NEW TIRES, TILTING THE VEHICLE AT DIFFERENT ANGLES SO THAT ALL SECTIONS ARE PROPERLY ROUGHENED. TIRES WILL NOT DISPLAY THEIR FULL GRIP CHARACTERISTICS UNTIL THEY ARE PROPERLY RUN IN. DRIVE AT A MODERATE SPEED FOR THE FIRST FEW KILOMETERS OF EACH TRIP TO ALLOW THE TIRES TO REACH THE NECESSARY OPERATING TEMPERATURE. MAXIMUM ROAD GRIP IS ASSURED WHEN THE TIRES ARE WARM. OBSERVE THE TRAFFIC REGULATIONS, DRIVE DEFENSIVELY AND TRYING TO LOOK AHEAD AS FAR AS POSSIBLE SO THAT ANY HAZ- ARDS CAN BE RECOGNIZED AS EARLY AS POSSIBLE. CHOOSE YOUR DRIVING SPEED ACCORDING TO THE CONDITIONS AND YOUR DRIVING SKILLS. DRIVE CAREFULLY ON UNKNOWN ROADS OR ON UNFAMILIAR TRI- ALS. RENEW THE VIZOR ON YOUR HELMET OR THE GLASS OF YOUR GOGGLES ON TIME SO AS TO ENSURE OPTIMUM VISION IN ANY SITUATION. WHEN LIGHT SHINES DIRECTLY ON SCRATCHED VISOR OR GOGGLES, THE OPERATOR WILL BE BLINDED. NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION IF THE ENGINE IS RUNNING. Accessories and payload Accessory parts and baggage can significantly decrease a motorcycle's driving stability. Please observe the following warnings. ONLY USE ACCESSORIES THAT HAVE BEEN RELEASED BY KTM. FOR EXAMPLE, FRONT PANELLING CAN IMPAIR THE DRIVING PROPERTIES OF THE MOTORCYCLE. CASES, EXTRA TANKS ETC. CAN ALTER THE WEIGHT DISTRIBUTION AND THUS ALSO IMPAIR THE VEHICLES DRIVING PROPERTIES. NEVER DRIVE FASTER THAN 30 KPH (80 MPH) IF YOU HAVE MOUNTED ACCESSORY PARTS ON YOUR MOTORCYCLE. ACCESSORY PARTS CAN SIGNIFICANTLY IMPAIR THE MOTORCYCLE'S HAN- DLING, ESPECIALLY IN THE MAXIMUM SPEED RANGE. NEVER DRIVE FASTER THAN 30 KPH (80 MPH) IF YOUR MOTOR- CYCLE IS LOADED WITH CASES OR OTHER BAGGAGE. THEY WILL IMPAIR THE MOTORCYCLE'S HANDLING AT HIGHER SPEEDS AND CAN EASILY CAUSE IT TO GO OUT OF CONTROL IF YOU HAVE CASES MOUNTED, DO NOT EXCEED THE MANUFAC- TURER'S RECOMMENDED MAXIMUM PAYLOAD. FASTEN THE BAGGAGE CLOSE TO THE CENTER OF THE MOTOR- CYCLE AND DISTRIBUTE THE WEIGHT EVENLY ON THE FRONT AND REAR WHEELS AND ON THE LEFT AND RIGHT. BAGGAGE MUST BE SECURELY AND ADEQUATELY FASTENEND; LOOSE BAGGAGE WILL SIGNIFICANTLY IMPAIR DRIVING SAFETY. A HIGH PAYLOAD WILL CHANGE THE MOTORCYCLE'S HANDLING AND CONSIDERABLY INCREASE THE BRAKING DISTANCE; ADAPT YOUR DRIVING SPEED ACCORDINGLY. NEVER EXCEED THE MAXIMUM PERMISSIBLE LADEN WEIGHT AND THE AXLE WEIGHTS. THE MAXIMUM PERMISSIBLE LADEN WEIGHT IS MADE UP OF THE FOLLOWING COMPONENTS: MOTORCYCLE READY FOR OPERATION AND TANK FULL LUGGAGE DRIVER WITH PROTECTIVE CLOTHING AND HELMET. 3

15 DRIVING INSTRUCTIONS» Check the following before each start When you start, the motorcycle must be in perfect mechanical condition. For safety reasons, you should make a habit of performing an overall check of your motorcycle before each start. The following checks should be performed: CHECK OIL LEVEL Insufficient oil results in premature wear and consequently to engine damage. FUEL Check that there is sufficient fuel in the tank. 4 3 CHAIN A loose chain can fall from the chain wheels; an extremely worn chain can tear, and insufficient luication can result in unnecessary wear of chain and chain wheels. 4 TIRES Check for damaged tires. Tires showing cuts or dents must be replaced. The tread depth must comply with the legal regulations. Also check the air pressure. Insufficient tread and incorrect air pressure deteriorate the driving performance. 5 BRAKES Check correct functioning of the aking system. Check for sufficient ake fluid in the reservoir. The reservoirs have been designed in such a way that ake fluid does not need to be refilled even when the ake pads are worn. If the level of ake fluid falls below the minimum value, this indicates a leak in the aking system or completely worn out ake pads. Arrange for the aking system to be checked by a KTM specialist, as complete failure of the aking system can be avoided. Also check the state of the ake hose and the thickness of the ake linings. Check free travel at hand ake lever and foot ake lever. 6 CABLES Check correct setting and smooth operation of all control s. 7 COOLING FLUID Check the level of cooling fluid when the engine is cold. 8 ELECTRICAL SYSTEM Check correct operation of headlamps, tail-lights, ake lights, indicators, control lamps and horn while the engine is running. 9 LUGGAGE If you are taking luggage with you, check that this is securely fastened. 0 REAR MIRROR Sit on the motorcycle and check the adjustment of the rear mirror.

16 DRIVING INSTRUCTIONS» Starting when the engine is cold Open the fuel tap [] Switch on ignition (turn ignition key [] into position ). 3 Switch on emergency OFF switch [3]. 4 Switch transmission to idle (green indicator lamp N [4] lights up). 5 Operate cold starting device (choke) [5]. 6 Do not accelerate; operate starter button [6]. 7 If the engine starts, push the choke lever back a little bit, as soon as the engine runs unevenly. 8 Take the motorcycle off of the main stand or side stand. TO AVOID INJURIES, IT IS RECOMMENDED TO WEAR BOOTS WHEN USING THE KICKSTARTER. DO NOT START THE ENGINE AND ALLOW IT TO IDLE IN A CLOSED ROOM. EXHAUST FUMES ARE POISONOUS AND CAN CAUSE LOSS OF CONSCIOUS- NESS AND DEATH. ALWAYS PROVIDE ADEQUATE VENTILATION WHILE THE ENGINE IS RUNNING. 3 4 MAXIMUM PERIOD FOR CONTINUOUS STARTING: 5 SECONDS. WAIT AT LEAST 5 SECONDS BEFORE TRYING AGAIN. DON T RIDE YOUR MOTORCYCLE WITH FULL LOAD AND DON T REV ENGINE WHEN COLD. BECAUSE THE PISTON IS WARMING UP FASTER THAN THE WATER COOLED CYLINDER, IT CAN CAUSE ENGINE DAMAGE. ALWAYS LET THE ENGINE WARM UP BEFORE AND REFRAIN FROM DRIVING WITH FULL LOAD UNTIL THE ENGINE IS WARM. If the engine is does not crank when you actuate the starter tip switch: the transmission is switched to idle Check if the emergency OFF switch is on Check if the ignition is on the headlight is on. If this is not the case, the battery is discharged If the lights are on, proceed as described in the Trouble-shooting section or contact a KTM dealer. 5 6 If the engine cranks but does not start, when you actuate the starter tip switch: Check if the fuel tap is open Check if the choke lever has been operated Check if sufficient fuel is in the tank If this is not the case, refill the tank if sufficient fuel is in the tank, proceed as described in the Troubleshooting section or contact a KTM dealer. 5 NOTE LC4 ENDURO / LC4 SUPERMOTO: This motorcycle is equipped with a safety starter system. The engine can only be started when the transmission is switched to idle or the clutch lever is pulled, respectively. Motorcycles with side stands are also equipped with a safety starting system. If you put in a gear with the side stand in its swung-out position, and if you let go of the clutch lever, the engine will stop. Starting when the engine is warm or hot Open the fuel tap [] Switch on ignition (turn ignition key [] into position ). 3 Switch on emergency OFF switch [3]. 4 Switch transmission to idle (green indicator lamp N [4] lights up). 5 Do not accelerate; operate starter button [6]. 6 Take the motorcycle off of the main stand or side stand. What to do when the engine is flooded The throttle must be fully opened when starting. If necessary change spark-plug.

17 6 DRIVING INSTRUCTIONS» Kickstart instructions Be sure to kick up the side stand before you start the engine to avoid any damage. Start as described above, then push the kickstarter hard ALL THE WAY. WHEN STARTING THE ENGINE, MAKE SURE THAT YOU ALWAYS WEAR STURDY MOTORCYCLING BOOTS IN ORDER TO AVOID INJURY. YOU MIGHT SLIDE OFF THE KICKSTARTER, OR THE ENGINE MAY CAUSE THE KICKSTARTER TO RECOIL, THEREBY CAUSING INJURIES TO FOOT AND LEG. ALWAYS KICK THE KICKSTARTER BRISKLY ALL THE WAY AND, WHILE DOING SO, NEVER OPEN THE THROTTLE. KICKSTARTING WITH INSUFFICIENT MOMENTUM AND AN OPENED THROTTLE LEVER INCREASES THE DANGER OF A POSSIBLE RECOIL. BEFORE YOU ACTUATE THE KICKSTARTER, BE SURE TO KICK UP THE SIDE STAND. Starting off Pull the clutch lever. Put the engine into first gear, slowly release the clutch lever and open throttle at the same time. BEFORE YOU START OFF, CHECK THAT THE MAIN STAND HAS BEEN SWUNG UP FULLY. IF THE STAND DRAGS ON THE GROUND, THE MOTORCYCLE CAN GO OUT OF CONTROL. Shifting/Riding You are now in first gear, refered to as the drive or uphill gear. Depending on the conditions (traffic, road gradient, etc.), you can shift to a higher gear. Close throttle, at the same time pull clutch lever and shift to the next higher gear. Let clutch lever go again and open throttle. If you turned on the choke, make sure you turn it off again as soon as engine is warm. When you reach full speed through turning the throttle grip all the way, turn throttle back to 3/4; the speed hardly decreases although the engine will use less gas. Never open the throttle wider than the engine can handle. Excessive turning of the throttle grip will increase full consumption. By shifting down, use the akes if necessary and close throttle at the same time. Pull clutch lever and shift down to the next gear. Let clutch lever go slowely and open throttle or shift down again. If, for example, the engine stalls at an intersection, simply pull the clutch lever and start. You do not need to shift into the neutral position. HIGH RPM RATES WHEN THE ENGINE IS COLD HAVE AN ADVERSE EFFECT ON THE LIFE OF YOUR ENGINE. WE RECOMMEND YOU RUN THE ENGINE IN A MODERATE RPM RANGE FOR A FEW MILES GIV- ING IT A CHANCE TO WARM UP. AFTER THAT NO FURTHER PRE- CAUTIONS IN THIS RESPECT NEED BE TAKEN. THE ENGINE HAS REACHED ITS OPERATING TEMPERATURE AS SOON AS THE RADI- ATORS BECOME WARM. NEVER HAVE THE THROTTLE WIDE OPEN WHEN CHANGING DOWN TO A LOWER GEAR. THE ENGINE WILL OVERSPEED, DAMAGING THE VALVES. IN ADDITION, THE REAR WHEEL BLOCKS SO THAT THE MOTORCYCLE CAN EASILY GET OUT OF CONTROL. LONG WHEELIES LEAD TO A DROP IN THE OIL PRESSURE WHICH CAN LEAD TO ENGINE DAMAGE. NEVER USE YOUR MOTORCYCLE WITHOUT AN AIR FILTER. OTHERWISE DUST AND DIRT MAY ENTER THE ENGINE AND CAUSE INCREASED WEAR. THE RED COOLANT WARNING LAMP LIGHTS UP WHEN THE COOLANT TEMPERATURE HAS REACHED 0 C. POSSIBLE CAUSES FOR THE INCREASE IN TEMPERATURE: -LOW DRIVING VELOCITY AND HIGH LOAD SITUATION IN HIGH AIR TEMPERATURES -LEVEL OF COOLANT IN THE SYSTEM IS INSUFFICIENT -FAN AT LEFT RADIATOR IS NOT RUNNING -IMPROPER USE OF THE CLUTCH WHILE DRIVING AT LOW VELOC- ITIES PLACE A CLOTH ON THE RADIATOR CAP. OPEN THE CAP SLOWLY, SO THE EXCESS PRESSURE IN THE COOLING SYSTEM CAN ESCAPE. - CAUTION SCALDING HAZARD! - AND CHECK THE COOLING LIQ- UID LEVEL. DO NOT DRIVE ON, UNTIL THERE IS SUFFICIENT LIQUID IN THE COLING SYSTEM. HOWEVER, CALL ON ONE OF KTM S DEALERS AS SOON AS POSSIBLE IN ORDER TO HAVE THE DEFECT REME- DIED. IF ANY ABNORMAL VIBRATIONS OCCUR WHILE DRIVING, CHECK THAT THE ENGINE FASTENING BOLTS ARE TIGHT. IN THE EVENT THAT, WHILE RIDING ON YOUR MOTORCYCLE, YOU NOTICE ANY UNUSUAL OPERATION-RELATED NOISE, STOP IMME- DIATELY, TURN THE ENGINE OFF, AND CONTACT AN AUTHORIZED KTM DEALER. Braking Close throttle and apply the hand and foot akes at the same time. When driving on sandy, wet or slippery ground use mainly the rear wheel ake. Always ake with feeling, blocking wheels can cause you to skid or fall. Also change down to lower gears depending on your speed. When driving downhill, use the aking effect of the engine. Change down one or two gears but do not overspeed the engine. In this way, you will not need to ake so much and the akes will not overheat. AVOID ABRUPT LOAD CHANGES WHILE RIDING AROUND BENDS AND ON WET OR SLIPPERY GROUND. OTHERWISE YOU MIGHT EAS- ILY LOSE CONTROL OVER YOUR MOTORCYCLE. WHILE RIDING YOUR MOTORCYCLE, NEVER SWITCH THE IGNITION LOCK TO POSITIONS AND. DO NOT TRY TO CHANGE THE SETTINGS WHILE DRIVING. YOUR ATTENTION WILL BE DISTRACTED FROM THE TRAFFIC AND MAY CAUSE YOU TO LOSE CONTROL OF YOUR MOTORCYCLE. AFTER FALLING WITH THE MOTORCYCLE, CHECK ALL FUNCTIONS THOROUGHLY BEFORE STARTING UP OPERATIONS AGAIN. IN THE RAIN, OR AFTER THE MOTORCYCLE HAS BEEN WASHED, BRAKING ACTION MAY BE DELAYED DUE TO WET BRAKE DISCS. FIRST, THE BRAKES MUST BE BRAKED DRY. ON SALT-SPRAYED OR DIRTY ROADS BRAKE ACTION MAY BE DELAYED AS WELL. FIRST, THE BRAKES MUST BE BRAKED CLEAN. WHEN YOU BRAKE, THE BRAKE DISCS, BRAKE PADS, BRAKE CALIPER AND BRAKE FLUID HEAT UP. THE HOTTER THESE PARTS GET, THE WEAKER THE BRAKING EFFECT. IN EXTREME CASES, THE ENTIRE BRAKING SYSTEM CAN FAIL. DIRTY BRAKE DISCS CAUSE INCREASED TEAR OF BRAKE PADS AND BRAKE DISCS.

18 DRIVING INSTRUCTIONS» Stopping and parking Apply the akes fully and put the engine into neutral. To stop the engine, switch off the ignition. Turn the fuel tap to the OFF position, park on an area where the ground is firm, and lock the motorcycle. ALWAYS PARK YOUR MOTORBIKE ON A SOLID AND HORIZONTAL SURFACE. NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS RUNNING. MOTORCYCLE ENGINES PRODUCE A GREAT AMOUNT OF HEAT WHILE RUN- NING. THE ENGINE RADIATORS, EXHAUST, EXHAUST SYSTEM, BRAKE DISCS, AND SHOCK ABSORBERS CAN BECOME VERY HOT. DO NOT TOUCH ANY OF THESE PARTS AFTER OPERATING THE MOTORCYCLE, AND TAKE CARE TO PARK IT WHERE PEDESTRIANS ARE NOT LIKELY TO TOUCH IT AND GET BURNED NEVER PARK YOUR MOTORCYCLE IN PLACES WHERE THERE EXIST FIRE HAZ- ARDS DUE TO DRY GRASS OR OTHER EASILY FLAMMABLE MATERIALS. NEVER LEAVE YOUR MOTORCYCLE WITHOUT SUPERVISION AS LONG AS THE ENGINE IS RUNNING. CLOSE THE FUEL TAP WHEN LEAVING YOUR VEHICLE.OTHERWISE THE CAR- BURETOR CAN OVERFLOW AND FUEL WILL ENTER THE ENGINE. ALWAYS TAKE OUT THE IGNITION KEY WHEN PARKING YOUR MOTORCYCLE SO THAT IT CANNOT BE USED BY UNAUTHORIZED PERSONS. INFORMATION ABOUT THE SIDE STAND: Use your foot to push the side stand forward as far as possible, and lean your motorcycle to the side. Make sure that your motorcycle is standing safely on solid ground. Just in case, you can also put in a gear. 7 PARK YOUR MOTORCYCLE, SO THAT IT RESTS STABLY ON THE SIDESTAND (HARD GROUND, LEVEL SURFACE) AND CAN T TIP OVER. THE SIDE STAND IS DIMENSIONED FOR THE WEIGHT OF THE MOTORCYCLE ONLY. IF YOU ARE SITTING ON THE MOTORBIKE AND THUS APPLY AN ADDI- TIONAL LOAD ONTO THE SIDE STAND, YOU MAY CAUSE DAMAGE TO THE SIDE STAND OR THE FRAME, AND YOUR MOTORBIKE MAY FALL OVER. NOTE REGARDING THE CENTER STAND: (is available as an accessory) We advise the following procedure to place the motorcycle on the center stand as effortlessly as possible: a) press main stand to ground using foot b) swing out kickstarter and pull motorcycle backwards at an angle as illustrated (see illustration). Make sure that the ground is solid and that your motorcycle is standing securely. THE CENTER STAND IS DESIGNED TO HOLD THE WEIGHT OF THE MOTORCYCLE ONLY. BY SITTING ON THE MOTORCYCLE, YOU WILL PUT ADDITIONAL WEIGHT ON THE CENTER STAND, POSSIBLY CAUSING THE CENTER STAND OR FRAME TO BE DAMAGED OR THE MOTORCYCLE TO FALL DOWN. Fuel In the condition at delivery, the LC4 engine requires unleaded premium-grade fuel with at least 95 octane (ROZ). If using lower octane fuel, it is easy to change over to the pre-programmed ignition curve for octane (ROZ) (see activating the ignition curve for low-octane fuel). USE UNLEADED PREMIUM-GRADE 95 OCTANE (ROZ) FUEL. IF USING LOWER OCTANE FUEL, THE IGNITION CURVE MUST BE CHANGED, OTHERWISE ENGINE DAMAGE WILL OCCUR. 35 mm GASOLINE IS HIGHLY FLAMMABLE AND POISONOUS. EXTREME CAUTION SHOULD BE USED WHEN HANDLING GASOLINE. DO NOT REFUEL THE MOTORCYCLE NEAR OPEN FLAMES OR BURNING CIGARETTES. ALWAYS SWITCH OFF THE ENGINE BEFORE REFUELLING. BE CAREFUL NOT TO SPILL GASOLINE ON THE ENGINE OR EXHAUST PIPE WHILE THE ENGINE IS HOT. WIPE UP SPILLS PROMPTLY. IF GASO- LINE IS SWALLOWED OR SPLASHED IN THE EYES, SEEK A DOCTOR S ADVICE IMME- DIATELY. Fuel expands when its temperature rises. Therefore do not fill the tank to the top (see fig.).

19 PERIODIC MAINTENANCE SCHEDULE» 8 ENGINE CARBURETOR ADD-ON-PARTS BRAKES CHASSIS WHEELS A WASHED MOTORCYCLE CAN BE CHECKED MORE QUICKLY WHICH SAVES MONEY!. Service after 000 km. Service after / every 5000 km Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 0,000 km Check and adjust valve clearance Check engine fastening screws for tight fit Make sure all engine screws accessible from the outside are screwed tight Check carburetor connection boots for cracks and leaks Check idle setting Check bleeder hoses for damage and kink-free arrangement Check cooling system for leaks, antifreeze protection Check radiator fan for proper operation Check exhaust system for leaks and suspension Check actuating s for damage, smooth operation, and kink-less arrangement,adjust and luicate them Check the oil level in the master cylinder of the hydraulic clutch Clean air filter and air filter box Check s for damage and kink-less arrangement Check headlamp adjustment Check electrical system for function (low/high beams, stop light, turn indicators,headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch) Make sure all screws and nuts are tight Check ake fluid level, lining thickness, and ake discs Check ake lines for damage and leaks Check/adjust smooth operation, free travel of handake/footake levers Check screws of ake system for tight fit Check suspension strut and fork for leaks and proper operation Check O-ring of suspension strut for wear Clean fork dust sleeves Bleed fork legs Check swinging-fork pivot Check/adjust steering-head bearing Luicate reversing lever Check all chassis screws for tight fit (fork plates, fork leg, axle nuts/screws, swinging-fork pivot, reversing lever, suspension strut) Check spoke tension and rim joint Check tire condition and inflation pressure Check chain and chain guides for wear, force fit and tension Check screws on pinion and chain sprocket for locking devices and a tight fit Luicate chain Check wheel bearings and jerk damper for play

20 PERIODIC MAINTENANCE SCHEDULE» IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Clean and luicate steering-head bearing and sealing elements Clean and adjust the carburetor Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease Change the ake fluid at least once a ar every ars or 0000 km IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! Service intervalls should never be exceed by moor than 500 km. Maintenance work done by KTM authorised workshops is not a substitute of care and checks done by the rider! 9 VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each start after every cleaning for cross country use Check oil level Check ake fluid level Check ake pads for wear Check lighting system for proper operation Check horn for proper operation Luicate and adjust actuating s and nipples Bleed fork legs in regular intervals Remove and clean fork dust sleeves in regular intervals Clean and luicate chain as necessary Check chain tension Clean air filter and filter box (depending on the dirt accumulation) Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber Check all control elements for smooth running Check ake performance Treat exposed metal components (except for the aking and exhaust systems) with wax-based anti-corrosion agents Treat ignition/steering lock and light switch with contact spray Check all screws, nuts, and hose clamps for their tight fit once a ar

21 MAINTENANCE WORK ON CHASSIS AND ENGINE» ALL SERVICING AND ADJUSTMENT PROCEDURES DESIGNATED BY AN ASTERISK * REQUIRE THE KNOWLEDGE AND SKILLS OF A PROFES- SIONAL. FOR YOUR OWN SAFETY, ALWAYS HAVE SUCH WORK PERFORMED BY A SPECIALIZED KTM DEALER WHERE YOUR MOTORCYCLE WILL BE OPTIMALLY SERVICED BY APPROPRIATELY QUALIFIED,SKILLED STAFF. WHEN CLEANING THE MOTORCYCLE, DO NOT USE A HIGH PRESSURE CLEANING UNIT IF POSSIBLE, OTHERWISE WATER WILL PENETRATE THE BEARINGS, CARBURETOR, ELECTRIC CONNECTORS ETC. WHEN TRANSPORTING YOUR KTM, ENSURE THAT IT IS HELD UPRIGHT WITH RESTRAINING STRAPS OR OTHER MECHANICAL FASTENING DEVICES. IF THE MOTORCYCLE SHOULD FALL OVER, FUEL CAN LEAK FROM THE CARBURETOR OR FUEL TANK DO NOT USE TOOTHED WASHERS OR SPRING WASHERS WITH THE ENGINE FASTENING SCREWS, AS THESE WORK INTO THE FRAME PARTS AND KEEP WORKING LOOSE. INSTEAD, USE SELF-LOCKING NUTS. LET YOUR MOTORCYCLE COOL DOWN BEFORE BEGINNING ANY MAINTENANCE WORK IN ORDER TO AVOID GETTING BURNED. DISPOSE OF OIL, GREASE, FILTERS, FUELS, CLEANING AGENTS ETC. ACCORDING TO YOUR LOCAL REGULATIONS. UNDER NO CIRCUMSTANCES MAY USED OIL BE DISPOSED OF IN THE SEWAGE SYSTEM OR IN THE OPEN COUNTRYSIDE. LITER USED OIL CONTAMINATES, LITERS WATER. IF YOU UNSCREWED ANY SCREWED CONNECTIONS WITH SELF-LOCKING NUTS, THEY MUST BE REPLACED WHEN MOUNTING. IF NO SELF- LOCKING NUTS ARE AVAILABLE, APPLY LOCTITE 43 TO THE THREAD. THE SCREWS AND NUTS MUST BE REPLACED IF THE THREAD IS DAMAGED. ALL SCREWS AND NUTS MUST BE TIGHTENED TO THE SPECIFIED TORQUE FIGURES USING A TORQUE WRENCH. IF SCREWS OR NUTS ARE NOT ADEQUATELY TIGHTENED, THEY CAN BECOME LOOSE AND CAUSE THE MOTORCYCLE TO GO OUT OF CONTROL WHILE YOU DRIVE. TIGHTENING THE SCREWS AND NUTS TOO TIGHTLY CAN DAMAGE THE THREAD AND COMPONENTS. 0 Tool set (LC4 Enduro) The tool set [] is located in the tool box under the right side cover. Removing the seat (LC4 Enduro) Remove the collar screws [] from the underside of the fender. Lift the rear of the seat, pull backwards, and unhook it from the oval-head screw [3]. 3 To mount the seat hook it into the oval head screw, lower the rear part of the seat and push the whole seat forwards. If necessary push the middle of the seat slightly down to let the retaining acket [4] engage with the seat. Finally fasten the seat with the corresponding screw. 4

22 MAINTENANCE WORK ON CHASSIS AND ENGINE» Removal of seat (LC4 Supermoto) Actuate the lever [] while lifting the back of the seat []. When you mount the seat, make sure the retaining ackets are fastened to the seat. 3 Tool set (LC4 Supermoto) The tool set [3] is located under the seat. 5 Checking and adjusting steering head bearing * Check steering head bearing for play periodicaly. To check this put motorcycle on a stand so that the front wheel is off the ground. Now try to move the fork forward and backward. To adjust, loosen the five clamp screws [4] of the top triple clamp and turn steering stem bolt clockwise [5] until there is no more play. Don t tighten the steering stem bolt all the way, otherwise the bearings will be damaged. With a plastic hammer, lightly rap on the triple clamp to avoid tension. Re-tighten the five clamp screws with 0 Nm IF THE STEERING HEAD BEARING IS NOT ADJUSTED TO BE FREE OF PLAY, THE MOTOR-CYCLE WILL SHOW AN UNSTEADY DRIVING PERFORMANCE AND CAN GET OUT OF CONTROL. IF YOU DRIVE WITH PLAY IN THE STEERING HEAD BEARING FOR LONGER PERI- ODS, FIRST THE BEARINGS AND THEN THE BEARING SEATS IN THE FRAME WILL BE DESTROYED. At least once a ar, the steering head bearings should be greased.

23 MAINTENANCE WORK ON CHASSIS AND ENGINE» Bleeder screws for telescopic fork After every 5 hours of use for competitive racing, slacken the eather plugs [] a few turns in order to relieve excess pressure from the inside of the fork. To do this, place the motorcycle on a stand with the front wheel lifted off the ground. When riding the motorcycle mainly on street, it will be enough to have this job performed in the course of the periodical maintenance service. EXCESSIVE PRESSURE IN THE INTERIOR OF THE FORK CAN CAUSE LEAKS IN THE FORK. IF YOUR FORK IS LEAKING, IT IS RECOMMENDED TO OPEN THE BREATHER PLUGS BEFORE HAVING THE SEALS REPLACED. Cleaning the dust sleeves of the telescopic fork The dust-protection bellows [] are to remove dust and coarse dirt particles from the fork tube. However, after some time, dirt may also get in behind the dust-protection bellows. If this dirt is not removed, the oil sealing rings located behind it may start to leak. Use a screwdriver to lever the dust-protection bellows out of the outer tubes and slide them downward. Clean the dust-protection bellows, outer tubes, and fork tubes thoroughly, and oil them thoroughly with Universal oil spray (Motorex Joker 440) or engine oil. Then, push the dust-protection bellows into the outer tubes by hand. NO OIL MAY REACH THE FRONT TIRE OR THE BRAKE DISKS SINCE THIS WOULD CONSIDERABLY REDUCE THE TIRE'S ROAD GRIP AND THE BRAKING EFFECT OF THE FRONT BRAKE.

24 MAINTENANCE WORK ON CHASSIS AND ENGINE» Changing the spring preload of the shock absorber KTM sets the shock absorber for a driver only, weighing approximately 75 kg (65 lb). If you want to take a passenger with you, of if you weigh considerably more or less than 75 kg (65 lb), you should change the spring preload accordingly [A]. This is easily done. NOTE: Before changing the spring preload note down the basic setting, e.g. how many threads are visible above the adjusting ring. One rotation of the adjusting ring [] changes the spring preload by approximately.75 mm (0.07 in). A Loosen the locking ring [] with the hook wrench from the tool set. Change the spring preload with the adjusting ring [] and retighten the locking ring. BASIC SETTING SPRING PRELOAD: WP 087A03...A = 3,5 mm WP 087A0...A = 0 mm (640 LC4) (640 LC4 Supermoto) 3 Luicating the shock absorber linkage The bearings in the rocker arm must be greased (Motorex Long Therm 000) in regular intervals. For this purpose, a grease nipple [3] is mounted on the rocker arm. AFTER EACH TIME THE MOTORCYCLE IS WASHED, IT IS ESPECIALLY IMPORTANT TO GREASE THE GREASE NIPPLE TO PUSH ANY WATER OUT OF THE BEARINGS. 3 Checking rubber ring on the WP rear shock absorber A rubber ring mounted on the rear shock absorber serves as a viation damper. This ring gets pressed together with time and loses its shock absorbing quality. Measure the distance between the two discs at various points around their circumferences. The space should be at least.5 mm (0. in) wide. Have the rubber ring replaced by an KTM dealer when compaction due to wear has exceeded this lower limit. min.,5 mm NOT REPLACING THE RUBBER RING IN TIME CAN RESULT IN DAMAGE TO THE REAR SHOCK ABSORBER. THE DAMPING UNIT OF THE SHOCK ABSORBER IS FILLED WITH HIGH COM- PRESSED NITROGEN. NEVER TRY TO TAKE THE SHOCK ABSORBER APART OR TO DO ANY MAINTENANCE WORK YOURSELF. SEVERE INJURIES COULD BE THE RESULT.

25 MAINTENANCE WORK ON CHASSIS AND ENGINE» Checking chain tension To check, jack up the motorcycle on the center stand or frame until it no longer touches the ground. Press the chain up approx. 30 mm behind the end of the chain sliding component. The chain should barely touch the swing arm when the upper chain part [A] is tensioned. If not, correct the chain tension. IF CHAIN TENSION IS TOO GREAT, PARTS WITHIN THE SECONDARY POWER TRANSMISSION (CHAIN, CHAIN SPROCKETS, TRANSMISSION AND REAR WHEEL BEARINGS) WILL BE SUBJECTED TO UNNECESSARY STRESS, RESULTING IN PREMATURE WEAR AND EVEN CHAIN BREAKAGE. TOO MUCH SLACK IN THE CHAIN, ON THE OTHER HAND, CAN RESULT IN THE CHAIN JUMPING OFF THE CHAIN WHEELS. IF THIS HAPPENS, THE CHAIN COULD ALSO BLOCK THE REAR WHEEL OR DAMAGE THE ENGINE. IN EITHER CASE THE OPERATOR IS LIKELY TO LOSE CONTROL OF THE MOTOR- CYCLE. A Correct chain tension Loosen collar nut [], loosen counter nuts [], and turn right and left adjusting screws [3] equally far. Tighten counter nuts []. Before tightening the wheel spindle, verify that the chain adjusters [4] are sitting close to the adjusting screws and that the rear wheel has been aligned with the front wheel. Tighten collar nut [] with 80 Nm. IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POS- SIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAVIOR OF YOUR MOTORCYCLE. NOTE: The large adjusting range of the chain adjusters 3mm (.8 in) allows you to use different secondary ratios in combination with the same chain length. The chain adjusters [4] can be rotated by 80. ALWAYS MOUNT THE CHAIN TENSIONER EQUALLY ALIGNED. 4

26 MAINTENANCE WORK ON CHASSIS AND ENGINE» Chain maintenance For long chain life, good maintenance is very important. X-ring chains require only modest maintenance. The best way is to use lots of water, but never use ushes or solvents. After letting the chain dry, you can use a special X-ring chain spray (Motorex Chainlube 6). NO LUBRICATION IS ALLOWED TO REACH THE REAR TIRE OR THE BRAKE DISK, EITHERWISE THE ROAD ADHERENCE AND THE REAR WHEEL BRAKING EFFECTS WOULD BE STRONGLY REDUCED AND THE MOTORCYCLE COULD EASILY GET OUT OF CONTROL. THE CHAIN DOES NOT HAVE A CHAIN JOINT FOR SAFETY REASONS. ALWAYS HAVE THE CHAIN REPLACED IN AN AUTHORIZED KTM WORKSHOP WHERE THE SERVICE TECHNICANS HAVE THE REQUIRED RIVETING TOOL. NEVER MOUNT A NORMAL CHAIN JOINT. Also check sprockets and chain guides for wear, and replace if necessary. 5 5 KG Chain wear In order to check the chain wear, regard the following instructions: Shift the gear into idling and pull the upper chain strand with approx. 0-5 kilogramm (33 lb) upwards (see figure). Now one can measure a space of 8 chain reels at the lower chain strand. The chain should be replaced at the latest when a space of 7 mm (0.88 in) is measured. Chains do not always wear off evenly, therefore repeat the measurement at different places on the chain. NOTE: If you mount a new chain, the sprockets should also be replaced. New chains wear faster if used on old used sprockets. max. 7 mm

27 MAINTENANCE WORK ON CHASSIS AND ENGINE» LC4 Enduro General informations about KTM disc akes BRAKE CALIPERS (LC4 Enduro): The ake calipers of this series float. This means that the ake calipers are not solidly attached to the caliper support. Thus, the ake pads are always in optimum contact with the ake disc. Secure the screws of the caliper support with Loctite 43 and tighten to 5 Nm. BRAKE CALIPERS (LC4 Supermoto): The front ake caliper [] has 4 ake pistons and is rigidly connected to the fork leg. The rear ake caliper has one ake piston and "floats", which means that it is not rigidly connected to the ake caliper support. The resulting lateral adjustment ensures that the ake pads [] optimally rest against the ake disk at any time. Secure the screws [3] of the caliper support with Loctite 43 and tighten to 40 Nm. LC4 Supermoto BRAKE PADS (LC4 Enduro): The ake pads are fitted with TOSHIBA TT 70 sintered lining at the front and ID450 organic lining at the back. 3 BRAKE PADS (LC4 Supermoto): The ake pads are fitted with ID450 organic lining These linings provide an optimal combination of dosing, ake performance and life cycle. The lining type is stated on the back of the ake pad and also recorded in the homologation papers. Other ake pads are available for competition sports. 6 BRAKE PADS AVAILABLE IN THE ACCESSORY TRADE ARE OFTEN NOT AUTHOR- IZED FOR OPERATION OF YOUR KTM MOTORCYCLE IN ROAD TRAFFIC. THE BRAKE PADS DESIGN AND FRICTION FACTOR AND THEREFORE THE BRAKING POWER CAN DEVIATE SIGNIFICANTLY FROM ORIGINAL KTM BRAKE PADS. IF YOU USE DIFFER- ENT BRAKE PADS THAN THOSE PROVIDED WITH THE ORIGINAL EQUIPMENT, IT CANNOT BE WARRANTED THAT THEY ARE AUTHORIZED FOR USE IN ROAD TRAF- FIC. YOUR MOTORCYCLE WILL NOT LONGER COMPLY WITH THE REGULATIONS AUTHORIZING THE USE OF VEHICLES FOR ROAD TRAFFIC AND THE WARRANTY WILL BE VOID. BRAKE FLUID: KTM fills the ake systems with Motorex Brake Fluid DOT 5. ake fluid, one of the best ake fluids that is currently available. We recommend that you continue to use it. DOT 5. ake fluid is based on glycol ether and of an amber color. If you do not have any DOT 5. for refilling, you may use DOT 4 ake fluid. However, you should replace it as soon as possible by DOT 5.. Never use DOT 5 aking fluid. It is based on silicone oil and has a purple color. Gaskets and ake hoses are not compatible with it. HAVE THE BRAKE FLUID CHANGED AT LEAST ONCE ANNUALLY. IF YOU WASH YOUR MOTORCYCLE OFTEN, THE BRAKE FLUID SHOULD BE CHANGED EVEN MORE FRE- QUENTLY. BRAKE FLUID TENDS TO ABSORB WATER. THEREFORE, VAPOR POCK- ETS MAY FORM IN "OLD" BRAKE FLUIDS EVEN AT LOW TEMPERATURES, CAUSING THE BRAKE SYSTEM TO FAIL. BRAKE FLUID RESERVOIRS: The ake fluid reservoirs on the front and rear wheel akes have been designed in such a way that even if the ake pads are worn it is not necessary to top up the ake fluid. If the ake fluid level drops below the minimum either the ake system has a leak or the ake pads are completely worn down. In this case, consult an authorized KTM dealer immediately. A B BRAKE DISCS: Wear reduces the thickness of the ake disc in the area of contact [4] with the ake pads. At its thinnest spot [A], the ake disc must not be more than 0.4mm thinner than its nominal dimension [B]. The nominal dimension can be gaged in a location beyond the area of contact with the ake pads. Check wear in several spots. 4 BRAKE DISCS SUFFERING FROM WEAR GREATER THAN 0.4 MM CONSTITUTE A SAFETY HAZARD. HAVE THE BRAKE DISC REPLACED IMMEDIATELY AS SOON AS IT REACHES ITS WEAR LIMIT. AS A MATTER OF PRINCIPLE, HAVE ANY REPAIR OF THE BRAKE SYSTEM CAR- RIED OUT BY A LICENSED KTM MECHANIC.

28 MAINTENANCE WORK ON CHASSIS AND ENGINE» min. 3 mm Adjusting of free travel at the hand ake lever (LC4 Enduro) Free travel at the hand ake lever may be readjusted by using adjusting screw []. In this way, the position of the point of pressure (i.e., the resistance you feel on the hand ake lever when the ake pads are pressed against the ake disc) can be adjusted for any hand size. When you press the hand ake lever forwards, you should have at least 3 mm (0. in) free travel. Turn the adjusting screw [] if necessary. AT THE HAND BRAKE LEVER, FREE TRAVEL MUST AT LEAST BE 3 MM (0. IN). ONLY THEN MAY THE PISTON IN THE HAND BRAKE CYLINDER BE MOVED (TO BE RECOGNIZED BY THE GREATER RESISTANCE OF THE HAND BRAKE LEVER). IF THIS FREE TRAVEL IS NOT PROVIDED, PRESSURE WILL BUILD UP IN THE BRAK- ING SYSTEM, AND THE FRONT WHEEL BRAKE MAY FAIL DUE TO OVERHEATING. 3 Changing the basic position of the handake lever (LC4 Supermoto) The adjusting screw [] allows you to change the basic position of the handake lever [3]. Press the handake lever's outer end forward, and, at the same time, turn the adjusting screw. 7 Checking of ake fluid level - front ake The ake fluid reservoir is linked with the hand ake cylinder at the handlebar and the reservoir is provided with an inspection glass. With the reservoir in a horizontal position, the ake fluid level should not go below middle of the glass. IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. 4 5 Refilling the front ake fluid reservoir * Loosen screws [4] and remove lid [5] and memane [6]. If necessary, dismount the mirror and loosen the throttle grip. Place hand ake cylinder in a horizontal position and fill the ake fluid reservoir to 5 mm (0. in) below the rim with ake fluid DOT 5. (Motorex Brake Fluid DOT 5.). Replace memane and lid, tighten screws. Rinse off spilled or overflowing ake fluid with water. 6 NEVER USE DOT5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PUR- PLE COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT. STORE BRAKE FLUID OUT OF REACH OF CHILDREN. BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES. IF YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR. 5 mm DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE PAINT REMOVER. USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER.

29 MAINTENANCE WORK ON CHASSIS AND ENGINE» min. mm Checking the front ake pads (LC4 Enduro) The ake pads can be inspected from below. The linings must be at least mm (0.04 in) thick. AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED. IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN AWAY, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC, IMPAIRING THE BRAKING EFFECT AND DESTROY- ING THE BRAKE DISC. min. mm Checking the front ake pads (LC4 Supermoto) The ake pads can be inspected from behind. Always inspect the ake pad linings before taking off on your motorcycle. They should not be thinner than mm (0.04 in) which is the case when the notch [A] is no longer discernable. AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN MM, OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED. 8 A IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN AWAY, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC, SIGNIFICANTLY IMPARING THE BRAKING EFFECT AND DESTROYING THE BRAKE DISC. B Changing the basic position of the foot ake pedal * The basic position of the foot ake pedal can be altered by turning the stop roller []. The free play at the foot ake pedal must then be adjusted by means of the piston rod []. Measured on the outside, the foot ake pedal must have 3-5 mm ( in) of free play, before the piston rod can move the piston in the ake cylinder (to be recognised from the resistance on the foot ake pedal). NOTE: To prevent the stop roller from turning when tightening, counteract by inserting a hexagon socket wrench in hole [B] provided for this purpose. 3-5mm IF THIS FREE PLAY IS NOT PRESENT, THEN PRESSURE CAN BUILD UP IN THE BRAKE SYSTEM WHEN DRIVING, CAUSING CONSTANT FRICTION OF THE BRAKE PADS.THE BRAKING SYSTEM OVERHEATS AND CAN FAIL COMPLETELY IN EXTREME CASES.

30 MAINTENANCE WORK ON CHASSIS AND ENGINE» Checking rear ake fluid level The reservoir for the rear disc ake is located on the left-hand side of the vehicle next to the carburetor carburetor connection boot. The ake fluid level may not drop below the MlN marking when the vehicle is in an upright position. IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM EITHER THE BRAKE SYSTEM HAS A LEAK OR THE BRAKE PADS ARE COMPLETELY WORN DOWN. IN THIS CASE, CONSULT AN AUTHORIZED KTM DEALER IMMEDIATELY. Refilling the rear ake fluid reservoir * When the ake fluid level has dropped to the MIN mark, you need to refill the ake fluid reservoir. For easier access to the ake fluid reservoir it is recommended to remove the hexagon screw []. Then move the container outwards as indicated in the illustration. Remove plug [] with rubber boot [3] and add ake fluid DOT 5. (Motorex Brake Fluid DOT 5.) up to the MAX mark. Replace rubber boot and plug. Overflown or spilled ake liquid must be rinsed off with water. Mount the screw and fix the ake fluid reservoir to the frame, always making sure to prevent kinks in the connecting hose. 3 NEVER USE DOT 5 BRAKE FLUID! IT IS BASED ON SILICONE OIL AND OF A PURPLE COLOR. SEALS AND BRAKE HOSES MUST BE ESPECIALLY ADAPTED TO IT. STORE BRAKE FLUID OUT OF REACH OF CHILDREN. BRAKE FLUID CAN CAUSE SKIN IRRITATION. AVOID CONTACT WITH SKIN AND EYES. IF YOU GET BRAKE FLUID IN YOUR EYES, RINSE WITH PLENTY OF WATER AND CONSULT A DOCTOR DON T LET BRAKE FLUID GET IN CONTACT WITH PAINT, IT IS AN EFFECTIVE PAINT REMOVER. USE ONLY CLEAN BRAKE FLUID TAKEN FROM A TIGHTLY SEALED CONTAINER. 9 min. mm Checking the rear ake pads The ake pads can be inspected from the rear. The thickness of the linings may not be less than mm (0.04 in). AT THEIR MOST WORN POINT BRAKE PAD LININGS SHOULD NOT BE THINNER THAN MM (0.04 IN), OTHERWISE THEY COULD LEAD TO BRAKE FAILURE. FOR YOUR OWN SAFETY DON T PUT OFF HAVING YOUR BRAKE PADS CHANGED. IF THE BRAKE PADS ARE REPLACED TOO LATE SO THAT THE LINING IS PARTLY OR ENTIRELY WORN AWAY, THE STEEL COMPONENTS OF THE BRAKE PAD WILL RUB AGAINST THE BRAKE DISC, IMPARING THE BRAKING EFFECT AND DESTROY- ING THE BRAKE DISC.

31 MAINTENANCE WORK ON CHASSIS AND ENGINE» Dismounting and mounting the front wheel (LC4 Enduro) To remove the front wheel, jack the motorcycle up on its frame so that the front wheel no longer touches the ground. Loosen both clamp screws [] on the left fork leg. Then loosen the collar nuts [] before loosening the clamp screws [] on the right fork leg. Hold the front wheel and withdraw the wheel spindle [3]. Note: The wheel spindle can be withdrawn more easily by turning it moderately with a 6 mm (0.4 in) ALLAN/IMBUS key while pulling. Carefully remove the front wheel from the fork. DO NOT OPERATE THE HAND BRAKE WHEN THE FRONT WHEEL HAS BEEN DISMOUNTED. ALWAYS PLACE THE WHEEL ON THE GROUND WITH THE BRAKE DISC POINT- ING UPWARDS. OTHERWISE THE BRAKE DISC MAY BE DAMAGED To install the front wheel, lift it into the fork, position and mount the axle shaft. Mount the collar nut [], tighten the clamping screws [] on the right fork leg axle passage to prevent the axle shaft from turning and tighten the collar nut to 40 Nm. Loosen the clamp screws on the right fork leg. Take the motorcycle down from its stand. Press the front wheel akes and push down on the fork a few times vigorously so that the fork legs come into alignment. Only after this has been accomplished, tighten the clamp screws on both fork legs with 0 Nm. IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE AXLE MAY LEAD TO AN UNSTABLE DRIVING BEHAV- IOR OF YOUR MOTORCYCLE. AFTER MOUNTING THE FRONT WHEEL, KEEP OPERATING THE HAND BRAKE UNTIL THE PRESSURE POINT RETURNS. IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND FATTY MATTERS, EITHERWISE THE BRAKING EFFECTS WOULD BE STRONGLY REDUCED. 4 Dismounting and mounting the front wheel (LC4 Supermoto) The front wheel of the Supermoto is essentially removed in the same manner as the front wheel of the LC4. However, the ake caliper has first to be removed. To remove the front ake caliper, remove both screws [4] and pull the caliper backwards from the ake disc. After mounting the front wheel, slide the ake caliper to the ake disc. Remove the grease from the threads of both screws [4] and apply Loctite 43. Tighten the screws with 40 Nm. THE SCREWS [4] MUST BE SECURED WITH LOCTITE 43.

32 MAINTENANCE WORK ON CHASSIS AND ENGINE» 3 Dismounting and mounting the rear wheel To remove the rear wheel, jack the motorcycle up on its frame so that the rear wheel no longer touches the ground. Loosen the collar nut [], remove chain tensioner [], hold the rear wheel and pull out the wheel spindle [3] until the rear wheel is free but the ake caliper support is still held. Push the rear wheel as far forward as possible, take the chain from the rear sprocket and carefully take the rear wheel out of the swingarm. DO NOT OPERATE THE REAR BRAKE WHEN THE REAR WHEEL HAS BEEN DIS- MOUNTED. ALWAYS PLACE THE WHEEL ON THE GROUND WITH THE BRAKE DISC POINT- ING UPWARDS. OTHERWISE THE BRAKE DISC MAY BE DAMAGED. IF THE AXLE IS DISMOUNTED, CLEAN THE THREAD OF THE WHEEL SPINDLE AND COLLAR NUT THOROUGHLY AND APPLY A NEW COAT OF GREASE (MOTOREX LONG THERM 000) TO PREVENT THE THREAD FROM JAMMING. NOTE: If the rear wheel has been dismounted, you should also check the shock absorption rubber. The rear wheel is remounted in reverse order. Before tightening the collar nut to 80 Nm, push the rear wheel forwards so that the chain tensioners lie on the tension screws. IF YOU DON T HAPPEN TO HAVE A TORQUE WRENCH AT HAND, MAKE SURE YOU HAVE THE TIGHTENING TORQUE CORRECTED BY A KTM DEALER AS SOON AS POSSIBLE. A LOOSE WHEEL SPINDLE MAY LEAD TO AN UNSTABLE DRIV- ING BEHAVIOR OF YOUR MOTORCYCLE. AFTER MOUNTING THE REAR WHEEL, KEEP OPERATING THE FOOTBRAKE UNTIL THE PRESSURE POINT RETURNS. IT IS VERY IMPORTANT TO KEEP THE BRAKE DISK FREE FROM OIL AND GREASE, OTHERWISE THE BRAKING EFFECT WOULD BE STRONGLY REDUCED. 3 4 Checking the shock absorption rubbers in the rear hub * LC4 models have a damped rear wheel hub. For this purpose, the engine power is conved from the rear sprocket via 6 shock absorption rubbers [4] to the rear wheel. These 6 absorption rubbers wear with increasing operation time, and should be checked for wear whenever the rear wheel is dismounted. For this purpose, lie the rear wheel on a work bench with the rear sprocket upwards, and put the wheel spindle in the hub. Now hold the rear wheel firmly and try to turn the rear sprocket. The rear sprocket may not turn more than maximum 5 mm (0, in) measured on the outside. If the play in the chain wheel is larger, all 6 shock absorption rubbers are to be replaced. Check the shock absorption rubbers for signs of damage and dirt. IF THE SHOCK ABSORPTION RUBBERS ARE NOT REPLACED IN GOOD TIME, THE REAR SPROCKET CARRIER AND THE REAR HUB WILL BE DAMAGED. ALLWAYS REPLACE ALL 6 ABSORPTION RUBBERS, NEVER SINGLE RUBBERS. max. 5 mm

33 MAINTENANCE WORK ON CHASSIS AND ENGINE» Tires, air pressure Tire type, tire condition, and how much air pressure the tires have in them affect the way your motorcycle rides, and they must therefore be checked whenever you re getting ready to go anywhere on your motorcycle. IN ORDER TO ENSURE RIDING SAFETY AND OPTIMAL RIDING PERFORMANCE, ONLY KTM-APPROVED TIRES MAY BE USED. OTHER TIRES CAN HAVE A NEGATIVE EFFECT ON RIDING PERFORMANCE (E.G. VIBRATION AT HIGHER SPEEDS). Approved tires for 640 LC4 (as of July 00) BRIDGESTONE TW 30/30 METZELER Enduro 3, Enduro 4, Karoo MICHELIN Sirac, T63 PIRELLI MT, MT60, MT70, MT90 3 TIRES - AIR PRESSURE 640 LC4 ENDURO front rear Road, Driver only,8 bar,0 bar Road, with passenger,0 bar, bar TIRES - AIR PRESSURE 640 LC4 SUPERMOTO front rear Road, Driver only,0 bar, bar Road, with passenger, bar,4 bar Tire type and size can be found in the technical specifications and in the homologation certificate Tire condition has to be checked every time you want to ride your motorcycle. Before leaving check for punctures and nails or other sharp objects that might have become embedded in the tire. Refer to the specific regulations in your country for minimum tire tread requirements. We recommend replacing tires at the latest when the tread is down to mm (0.08 in). Tire pressure should be checked regularly on a cold tire. Proper pressure ensures optimum driving comfort and extends the life of your tires. Do not mount tires which have not been approved by KTM. Other tires could have adverse effects on the way your motorcycle rides. Use tires of the same and and type for the front and rear wheels. For your own safety replace damaged tires immediately. Worn tires can have a negative effect on how your motorcycle performs, especially on wet surfaces. If air pressure is too low, abnormal wear and overheating of the tire can result. New wheels have a smooth surface, which means that they must be run in to achieve full grip. For this purpose, ride the motorcycle carefully at moderate speed during the first 00 kilometers with new tires, tilting the vehicle at different angles so that all sections are properly roughened. Tires will not display their full grip characteristics until they are properly run in. For reasons of safety, it is recommended to exchange the valve insert whenever a new tire is mounted. Checking spoke tension The correct spoke tension is very important for the stability of the wheels and thus for riding safety. A loose spoke causes the wheel to become unbalanced and before long other spokes will have come loose. Check spoke tension, especially on a new motorcycle, in regular intervals. For checking, tap on each spoke with the blade of a screw driver (see illustration). A clear tone must be the result. Dull tones indicate loose spokes. If necessary, have the spokes retightened and the wheel centered by a KTM dealer. 0 sec SPOKES CAN TEAR IF YOU CONTINUE TO RIDE WITH THEM LOOSE. THIS MAY LEAD TO AN UNSTABLE HANDLING OF YOUR MOTORCYCLE. EXCESSIVELY TENSIONED SPOKES MAY RUPTURE DUE TO LOCAL OVERLOAD- ING.THE SPOKES MUST BE TENSIONED TO 4 NM. Changing the wheel size The preset wheel diameter (, 9 or 7 ) and the respective wheel circumference (05, 040 or 88 mm) are displad iefly when the ignition is switched on. To change the wheel diameter, switch on the ignition, change to the ODO mode and press the MODE and SET buttons simultaneously for approx. 0 seconds. The display will start to blink. Select the wheel diameter using the MODE button, press the SET button to confirm and save the setting.

34 MAINTENANCE WORK ON CHASSIS AND ENGINE» Enduro Battery The battery is located under the seat and is maintenance-free. It is not necessary to check the electrolyte level or to refill water. Simply keep the battery poles clean and slightly grease them with an acid-free grease if necessary. Removing the battery: Remove screws [] and swing retaining acket and voltage regulator out of the way. First disconnect the negative and then the positive pole of the battery. Remove battery. When replacing, connect first the positive and then the negative pole. Supermoto IF ELECTROLYTE (SULPHURIC ACID) LEAKS FROM THE BATTERY, PROCEED WITH GREAT CARE. THE ELECTROLYTE CAN CAUSE SEVERE BURNS. IN THE CASE OF SKIN CONTACT RINSE THOROUGHLY WITH WATER. IN THE CASE OF CONTACT WITH THE EYES, THOROUGHLY RINSE EYES WITH WATER FOR AT LEAST 5 MINUTES. IMMEDIATELY CONSULT A DOCTOR. THE BATTERY IS A CLOSED MODEL BUT CAN NEVERTHELESS EMIT EXPLO- SIVE GASES. AVOID SPARKS AND OPEN FIRE NEAR THE BATTERY. DEFECTIVE BATTERIES MUST BE STORED OUT OF THE REACH OF CHILDREN. ENSURE PROPER DISPOSAL OF DISCARDED BATTERIES. TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR []! NEVER DISCONNECT THE BATTERY WHILE THE ENGINE IS RUNNING. THIS WILL DESTROY THE RECTIFIER-REGULATOR. THE BATTERY MUST BE INSTALLED WITH THE TERMINALS FACING THE FRONT (AS SHOWN IN THE ILLUSTRATION), OTHERWISE ELECTROLYTE CAN ESCAPE. 33 BATTERY STORAGE: When preparing the motorcycle for a longer period of standstill, remove the battery and recharge it. Storage temperature: 0-35 C (30-95 F). Do not expose to direct sunlight. Charging the battery NOTE: A battery charger, item no is available from your KTM dealer. You can also use the battery charger to test the battery's off load voltage, startability and the generator capacity. Remove the battery and check the charging level. Use a voltmeter to measure the voltage between the battery poles (off-load voltage). Accurate results can only be obtained if the battery has neither been charged nor discharged during a period of 30 minutes preceding the measuring. Recharging is not required if the voltage exceeds.4 V. Recharge if the voltage is below.4 V. CHARGING: Charge the battery for 5 to a max. of 0 hours with 0.9 amperes and a max. of 4.4 volts. For a quick charge, do not charge the battery longer than hour with 4.5 amperes and a max. of 4.4 volts. VOLT IF THE CHARGE CONDITION CANNOT BE ESTABLISHED, THE BATTERY MAY ONLY BE CHARGED 5 TO A MAX. OF 0 HOURS WITH 0.9 AMPERES AND A MAX. OF 4.4 VOLTS. ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE CHARGING UNIT ON. WHEN RECHARGING THE BATTERY IN CLOSED ROOMS THERE IS SUFFICIENT VENTILATION. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING PROCESS. CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED VALUES. OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY VALVES. AVOID QUICK CHARGING IF POSSIBLE. TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR.

35 MAINTENANCE WORK ON CHASSIS AND ENGINE» Fuses Fuse box [A] is located under the seat. See "Removing the seat" to remove and mount the seat. The fuses are numbered on the inside of the fuse box. The fuses marked "RES" are spare fuses. FUSE LC4 SUPERMOTO LC4 ENDURO A 0 Ampere electronic speedometer capacitor 0 Ampere ignition starter system 0 Ampere protects all power consumers against short circuits. 0 Ampere electronic speedometer capacitor 34 Enduro Supermoto Ampere flasher lights ake light horn 0 Ampere headlight parking light 0 Ampere ignition starter system 0 Ampere flasher lights ake light horn 0 Ampere headlight parking light Replace a blown fuse only with an equivalent one. If a new fuse that has just been set in gets blown again, you are strongly advised to have it inspected by a KTM dealer. A UNDER NO CIRCUMSTANCES IS A STRONGER FUSE ALLOWED TO BE SET IN OR A FUSE ALLOWED TO BE REPAIRED. AN INEXPERT TREATMENT COULD DAM- AGE THE WHOLE ELECTRICAL INSTALLATION! Exchanging the ake light and tail light bulb (LC4 Enduro) Remove the cap [] on the underside of the license plate retainer. Turn the lamp socket [] approximately 30 counterclockwise and pull it out of the tail light housing. Slightly depress the bulb, turn it approx. 30 counterclockwise and pull it out of the socket. To mount the lamp reverse the worksteps indicated above. NOTE: Since the bulb on the tail end is subjected to higher viations, heavyduty bulbs are available from your KTM dealer.

36 MAINTENANCE WORK ON CHASSIS AND ENGINE» Exchanging the ake light and tail light bulb (LC4 Supermoto) Remove seat. Disengage retaining clip [] and take bulb out of reflector. When changing the ake-light lamp, simply pull it out of the holder. Slightly depress the bulb, turn it approx. 30 counterclockwise and pull it out of the socket. To mount the lamp reverse the worksteps indicated above. When changing the tail-light lamp [], simply pull it out of the holder. 35 Exchanging the headlight lamp (LC4 Enduro) Replacing the headlight bulb Remove the headlight mask: Remove screw [3] on the left and right. Tilt the headlight mask to the front and detach from the lower fender. 3 Exchanging the headlight lamp: Disconnect plug [4] from the bulb. Remove the rubber cap [5] Unhook the retaining acket, then remove the bulb. When inserting the new bulb make sure that the wider of the 3 tongues [6] is located in the corresponding groove in the socket. 5 4 NEVER TOUCH THE GLASS OF THE BULB WITH YOUR FINGERS. THE GLASS OF THE BULB MUST REMAIN ABSOLUTELY FREE FROM GREASE. HEAT WILL OTHER- WISE CAUSE THE GREASE TO EVAPORATE AND SETTLE DOWN ON THE REFLECTOR. Hook in the retaining acket, mount the rubber cap and connect the plug to the bulb. Mount the headlight mask: Position the headlight mask such that the headlight is located under the cockpit. Fit the headlight mask into the fender and mount screws [3]. 7 Replacing the parking-light bulb (LC4 Enduro) Disassemble the headlight as described above and simply pull the bulb socket [7] out of the reflector. 6

37 MAINTENANCE WORK ON CHASSIS AND ENGINE» Exchanging the headlight lamp (LC4 Supermoto) Removing the headlight mask: Remove the left and right screws [] and the speedometer cover. Detach the headlight mask and tilt towards the front. Replacing the headlight lamp: Pull the plug [] off the bulb Remove the rubber cap [3] Turn the lamp base [4] approx. 30 in a counterclockwise direction and pull out of the socket. When inserting the new bulb make sure that the wider of the 3 blades [5] fits firmly in the respective socket recess. 3 NEVER TOUCH THE GLASS OF THE BULB WITH YOUR FINGERS. THE GLASS OF THE BULB MUST REMAIN ABSOLUTELY FREE FROM GREASE. HEAT WILL OTHER- WISE CAUSE THE GREASE TO EVAPORATE AND SETTLE DOWN ON THE REFLECTOR. 6 To mount, proceed in the reverse order. Mounting the headlight mask: Fit the headlight mask in the respective ackets. Mount the speedometer cover and screws [] Replacing the parking-light bulb (LC4 Supermoto) Disassemble the headlight as described above and simply pull the bulb socket [6] out of the reflector. 5

38 MAINTENANCE WORK ON CHASSIS AND ENGINE» Cooling system Coolant is circulated by a water pump located in the engine. When the engine is cold the cooling liquid circulates only through the cylinder and the cylinder head. After the engine has reached its operating temperature (about 70 C, 58 F), the thermostat opens and the cooling liquid is also pumped through both aluminum radiators. Air blowing in through the radiators cools the cooling liquid. The slower the speed of the motorcycle, the less the cooling liquid is cooled down. Dirty radiator fins also reduce the cooling efficiency. If little or no air blows through the radiators, for example when riding through slow traffic or waiting at traffic lights, the coolant temperature will rise. If the coolant temperature rises to 98 C, the fan [] on the left radiator will switch on. This fan will provide additional air circulation through the radiator thereby preventing the cooling system from overheating. THE RED TEMPERATURE WARNING LAMP FOR THE COOLING LIQUID [] WILL BEGIN TO BLINK WHEN THE COOLING LIQUID HAS REACHED APPROX. 0 C (46 F), EXCEEDING THE NORMAL OPERATING TEMPERATURE. POSSIBLE CAUSES: SLOW RIDING WITH LARGE LOADS AT A HIGHER AIR TEMPERATURE: IF POSSIBLE INCREASE YOUR RUNNING SPEED, SO THAT MORE AIR CAN BLOW THROUGH THE RADIATORS. SHOULD THE WARNING LIGHT STILL BE ON OFF AFTER 300 METERS, STOP IMMEDIATELY, SWITCH OFF THE ENGINE AND LOOK FOR OTHER POSSIBLE CAUSES. TOO LITTLE COOLING LIQUID IN THE SYSTEM: LET THE ENGINE COOL DOWN, AND CHECK THE SYSTEM FOR LEAKAGE S. ALSO EXAMINE THE COOLING LIQUID LEVEL CAUTION SCALDING HAZARD! DO NOT DRIVE ON, UNTIL THERE IS SUFFICIENT LIQUID IN THE COOLING SYSTEM. GO TO YOUR NEAREST KTM GARAGE AND GET IT SEEN TO. IF YOU DRIVE WITH THE COOLING LIQUID TEMPERATURE WARNING LIGHT ON, YOU WILL CAUSE EVEN MORE DAMAGES TO THE ENGINE. THE COOLING FAN ON THE LEFT COOLER IS NOT WORKING: THE COOLING FAN MUST BE RUNNING, WHEN THE COOLING LIQUID TEMPER- ATURE IS 98 C AND THE IGNITION IS ON. IF THE FAN IS NOT WORKING, AND THERE APPEARS TO BE SUFFICIENT COOLING LIQUID, THE ONLY THING YOU CAN DO IS TO DRIVE ON TO YOUR NEAREST KTM GARAGE AT THE LEAST POS- SIBLE ENGINE LOAD. CONTINUOUS USE OF THE CLUTCH (RIDING THE CLUTCH) AT LOWER SPEEDS A mixture of 50% antifreezer and 50% water is used as cooling liquid. However, the anti-freeze protection must be at least -5 C (-3 F). Aside from antifreezing protection, this mixture also provides great corrosion protection which is why it must not be replaced by pure water. FOR THE COOLING SYSTEM, USE ONLY HIGH-GRADE ANTIFREEZER (MOTOREX ANTI- FREEZE). USING LOWERGRADE ANTIFREEZE AGENTS, CAN CAUSE CORROSION AND COOLANT FOAMING. 0 mm when engine is cold Pressure induced by heating of the cooling liquid in the cooling system is controlled by a valve in the radiator cap [3]; a water temperature rising up to 5 C (55 F) is admissible, without fear of problems. Checking the cooling liquid level The cooling liquid should be 0 mm (0.4 in) above the cooling elements when the engine is cold (cf. diagram). In the event of the cooling liquid being drained, always fill the system before hand, then top off while the engine is running. IF POSSIBLE, ALWAYS CHECK LEVEL OF COOLING LIQUID WHEN ENGINE IS COLD. IF YOU HAVE TO OPEN THE RADIATOR CAP WHEN THE ENGINE IS HOT, USE A RAG TO COVER THE CAP AND OPEN SLOWLY TO RELEASE PRESSURE. CAUTION - SCALDING HAZARD! DO NOT DETACH ANY RADIATOR HOSES WHILE THE ENGINE IS HOT. THE ESCAPING HOT COOLANT AND THE STEAM MAY CAUSE SERIOUS BURNS. IN CASE YOU GET BURNT, HOLD THE AFFECTED PART OF YOUR BODY UNDER RUNNING COLD WATER RIGHT AWAY! COOLANT IS TOXIC. KEEP THE COOLANT OUT OF THE REACH OF CHILDREN! IN CASE COOLANT IS INGESTED, GO SEE A DOCTOR IMMEDIATELY! IF COOLANT GETS INTO YOUR EYES, RINSE THEM OUT WITH WATER IMMEDI- ATELY AND GO SEE A DOCTOR!

39 MAINTENANCE WORK ON CHASSIS AND ENGINE» Cleaning the air filter (LC4 Enduro) * It is very important for the engine's life expectancy to clean the air filter regularly. To clean the air filter, remove screws [] and the filter box cover. Detach retaining clip [] and remove the air filter [3] including the filter holder [4] from the filter box. 3 Remove the air filter from the filter holder and wash thoroughly in special cleaning fluid. Motorex offers environmentally-friendly products for professional oil filter maintenance (Motorex Bio Dirt Remover + Motorex Liquid Bio Power). Press out the water from the air filter but do not wring and allow the filter to dry. Luicate the dry air filter thoroughly with highgrade filter oil, rubbing to coat the entire filter surface. Clean the filter box and cover and check the carburetor connection boot for damage Mount the air filter on the filter holder, position in the filter box (make sure to center) and fix with the retaining clip. Check whether the air filter is positioned correctly and mount the filter box cover. 4 DO NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE WILL DAMAGE THE FOAM. KTM RECOMMENDS THE PRODUCTS MADE BY TWIN AIR FOR AIR FILTER MAINTENANCE. FOR CLEANING PURPOSES AND TO OIL THE AIR FILTER. NEVER START YOUR MOTORCYCLE WITHOUT ANY AIR FILTERS. OTHERWISE, DUST AND DIRT MAY PENETRATE AND CAUSE DAMAGE AND INCREASED WEAR. DUST AND DIRT CAN ACCUMULATE AND DAMAGE THE ENGINE IF THE AIR FIL- TER IS NOT MOUNTED CORRECTLY. 5 Cleaning of air filter (LC4 Supermoto) * To do this, remove the seat and the air filter cover from the air filter box. Unclap the filter holder [5], swing back and remove air filter plus filter carrier from the filter box. Remove the air filter from the filter holder and wash thoroughly in special cleaning fluid. Motorex offers environmentally-friendly products for professional oil filter maintenance (Motorex Bio Dirt Remover + Motorex Liquid Bio Power). Press out the water from the air filter but do not wring and allow the filter to dry. Luicate the dry air filter thoroughly with highgrade filter oil, rubbing to coat the entire filter surface. Clean the filter box and cover and check the carburetor connection boot for damage. Mount the air filter on the filter support [6]. Grease the front side [A] of the filter, to improve the seal. Mount the air filter and the filter support in the filter box. Make sure they are centered [B], and lock into place with the filter holder [5]. B 6 A 5 DO NOT CLEAN AIR FILTER WITH FUEL OR PETROLEUM SINCE THESE DAM- AGE THE FOAM. KTM RECOMMENDS THE PRODUCTS OF THE COMPANY MOTOREX FOR AIR FILTER MAINTENANCE. NEVER OPERATE YOUR MOTORCYCLE WITHOUT AIR FILTER. OTHERWISE, DUST AND DIRT MAY GET INTO THE ENGINE AND LEAD TO INCREASED WEAR. HAVING MOUNTED THE AIR FILTER, CHECK IT FOR CORRECT FIT. THE FRONT END A MUST ABOUT THE AIR FILTER BOX. OTHERWISE, DUST AND DIRT MAY GET INTO THE ENGINE AND LEAD TO INCREASED WEAR.

40 MAINTENANCE WORK ON CHASSIS AND ENGINE» Exhaust system (LC4 Supermoto) * 640 Supermoto silencers are filled with glass-fiber yarn in the front and insulation matting in the rear for dampening. The influence of heat causes the glass-fiber yarn to become loose. This can lead to a loss of power and reduce the silencer's dampening effect, therefore only the front glass-fiber yarn set [] must be replaced. To replace, detach the silencer from the motorcycle and remove the front cap []. Pull the front glass-fiber yarn set including the inner exhaust pipe [3] out of the silencer. Clean the front inner exhaust pipe. Slide a new set into the silencer.replace O-Ring [4]. Then push the inner exhaust pipe into the silencer and mount the cap. 4 THE EXHAUST SYSTEM BECOMES VERY HOT WHILE THE MOTORCYCLE IS RUN- NING. TO AVOID BURNS DO NOT START WORK ON THE EXHAUST SYSTEM UNTIL IT HAS PROPERLY COOLED DOWN Changing the original position of the clutch lever The adjusting screw [5] can be used for individual adjustment of the original position of the clutch lever, thus allowing adjustment to an optimal position for every hand size. Turning the adjusting screw clockwise reduces the distance between the clutch lever and the handlebar. Turning the adjusting screw counterclockwise increases the distance between the clutch lever and the handlebar. ADJUSTMENT OF THE CLUTCH LEVER POSITION IS ONLY POSSIBLE WITHIN CER- TAIN LIMITS. ONLY TURN THE ADJUSTING SCREW MANUALLY AND NEVER APPLY EXCESSIVE FORCE. 7 6 Checking the oil level of the hydraulic clutch * To check the oil level in the master cylinder of the clutch remove the cover. For this purpose, remove screws [6] and cover [7] together with the rubber boot [8]. The oil level in the horizontal-standing master cylinder should be 4 mm (0.6 in) below the upper edge. If necessary, add SAE 0 biodegradable hydraulic oil (Motorex Kupplungsfluid 75), available from your authorized KTM workshop. 8 KTM USES BIODEGRADABLE, HYDRAULIC MINERAL OIL TO ACTUATE THE HYDRAULIC CLUTCH. DO NOT MIX THIS OIL WITH ANY OTHER HYDRAULIC OIL. ALWAYS USE ORIGINAL KTM HYDRAULIC OIL (AVAILABLE FROM YOUR AUTHORIZED KTM WORK- SHOP) TO MAKE SURE YOUR CLUTCH OPERATES SMOOTHLY. NEVER REFILL WITH BRAKE FLUID.

41 MAINTENANCE WORK ON CHASSIS AND ENGINE» 4 mm Checking and adjusting the choke play * The choke lever must always have a play of approx. 4 mm (0.6 in). IF THERE IS NO PLAY IN THE CHOKE CABLE, THE BORE OF THE COLD STARTER SYSTEM CANNOT BE COMPLETELY CLOSED. THIS RESULTS IN HIGH FUEL CON- SUMPTION, AN UNEVEN RUNNING ENGINE, AND AN EXTREME WEAR OF PISTON AND CYLINDER. Remove the seat and tank to adjust. 3 Push the choke lever all the way to the front and slide the protecting cap [] from the adjusting part []. Loosen the lock nut [3] and correct the play by turning the adjusting part. Tighten lock nut and slide protecting cap back on. Mount the tank and seat mm Checking the adjustment of the hand decompression * To check, set piston at compression, so that the valves are closed. While doing this, slowly operate the kickstarter through its stroke until the clicking sound (disengaging) of the automatic decompression can be heard. Now the decompression lever must be operated 5 mm ( in) until resistance is felt (the exhaust valves begin to open). To adjust move back the protective cover [4], loosen the counter nut and correct the adjusting screw [5] accordingly. Tighten counter nut and push back protective cover. IF THERE IS NO PLAY IN THE DECOMPRESSION LEVER, THIS CAN RESULT IN ENGINE DAMAGE. note: No adjustment need be made to the automatic decompressor. 3-5 mm Adjust the throttle * When starting to turn the throttle grip, you should feel an initial backlash of 3-5 mm (0.-0. in) If a correction is necessary, start by removing the tank. Slide back the protection cover [6]. To set the backlash, loosen the counter nut [7] and turn the adjusting screw [8] accordingly. Then, fasten the counter nut and slide the protection cover back on. Make sure that the throttle grip will return to the idle position automatically once you let go of it. To check the correctness of this setting, start the engine, turn the handlebar left and right, in both cases as far as it will go. This must not cause any changes in idling speed. Otherwise, you have to increase the backlash of the throttle.

42 MAINTENANCE WORK ON CHASSIS AND ENGINE» Activating the ignition curve for low-octane fuel If you are traveling to a country where fuel having at least 95 octane (ROZ) is not available, you can easily activate the corresponding ignition curve. A socket connector [] is located on a own-black near the digital box. If the two connectors are connected to each other, the ignition curve for fuel having at least 95 octane (ROZ) is activated. If you disconnect the plug and socket connection, the ignition curve for fuel having octane (ROZ) is activated. Although this causes the engine to lose some of its power output, it prevents poor glow ignitions and engine damage. IF FUEL HAVING AT LEAST 95 OCTANE (ROZ) IS NOT AVAILABLE, THE IGNITION CURVE FOR OCTANE (ROZ) MUST BE ACTIVATED TO PREVENT ENGINE DAMAGE. 4 Adjust idling speed * Use the adjusting screw [] to adjust the basic position of the throttle valve and, thus, the idle speed.turning in clockwise direction will increase the idling speed, turning in counterclockwise direction will reduce the idling speed. Normal idling speed rpm. Draining the carburetor float chamber * Following every wet-cleaning procedure, the float chamber of the carburetor should be drained in order to remove any water that may have penetrated into it. Water in the float chamber causes engine malfunction. Carry out this job with the engine being cold. Close the fuel tap. Put one end of the hose [3] that leads downward behind the engine into a collecting vessel. 3 Open the drain plug [4] (turning it counterclockwise) by several turns, and drain the fuel from the float chamber. Then, retighten the drain plug and open the fuel tap. 4 3 FUEL IS HIGHLY FLAMMABLE AND TOXIC. BE EXTREMELY CAUTIOUS WHEN HAN- DLING FUEL. NEVER PERFORM ANY WORK ON THE FUEL SYSTEM NEAR OPEN FIRE OR BURNING CIGARETTES. ALWAYS ALLOW THE ENGINE TO COOL DOWN FIRST. WIPE UP ANY SPILT FUEL IMMEDIATELY. MATERIALS SATURATED WITH FUEL ARE HIGHLY FLAMMABLE, AS WELL. IF YOU HAVE ACCIDENTALLY SWALLOWED FUEL OR IF IT HAS GOTTEN INTO YOUR EYES, GO SEE A PHYSICIAN IMMEDIATELY.

43 MAINTENANCE WORK ON CHASSIS AND ENGINE» 5W/40 JASO T903 MA TEMPERATUR 0 C 3 F 0W/50 Engine oil Automobile engine oil used to be used for four-stroke motorcycles before there were separate motorcycle specifications. Different technical developments made it necessary to have a separate specification for four-stroke motorcycles - the JASO T903 MA standard. Whereas car engines require long changing intervals, motorcycle engines require a higher power output at higher speeds. Most motorcycle engines also use the same oil to luicate the transmission and the clutch. The JASO MA standard responds to these special requirements. Only use fully synthetic engine oils that meet the JASO MA quality requirements (see information on the can). KTM recommends Motorex Power Synt 4T in the 0W/50 viscosity (for temperatures over 0 C, 3 F) or 5W/40 (for temperatures under 0 C, 3 F) B Checking the engine oil level The engine oil level can be checked when the engine is cold or warm. To check, place the motorcycle in an upright position on a level surface (center stand). If the engine is cold, the oil level should be visible at the lower edge [A] of the inspection glass. If the engine is warm, the oil level should be visible at the upper edge [B] of the inspection glass. Add engine oil if necessary. 4 A INSUFFICIENT AMOUNTS OF OR LOW-GRADE ENGINE OIL LEAD TO PREMA- TURE WEAR IN THE ENGINE. DO NOT OVERFILL THE ENGINE CASE. DO NOT UNDERFILL THE ENGINE CASE Oil circuit The oil pump [] pumps the motor oil past the bypass valve [] and through the oil filter [3]. Beyond the oil filter, one of the oil lines forks off to a jet [4] that injects motor oil to the piston pin bearing and the piston head. The second oil line leads the main oil flow to the frame east pipe [5] where the motor oil is cooled off. Then the motor oil flows through the fine screen filter [6] that removes even the finest of contaminants from the motor oil. The cleansed motor oil is pumped via an oil line and the clutch cover into the crankshaft to the conrod bearing [7] and drains from there into the crank case. A additional oil pump [8] suctions the motor oil out of the crank case and pumps it through the oil canal [9] to the gear wheels of the 4th and 5th gears. The motor oil reaches the oil sump via the gear wheels. The timing chain [0] also dips into the oil sump and propels motor oil upwards to the cylinder head. The motor oil reaches the carnshaft [] and the valves through the bore []

44 MAINTENANCE WORK ON CHASSIS AND ENGINE» 3 4 A Oil and screen filter change, bleeding of the oil system * Note: The frame east pipe is integrated into the oil circuit for the sake of more effectively cooling the motor oil. It is thus important when changing the oil to also remove the fine screen filter, to drain the motor oil from the east pipe and to de-aerate the oil system. If the oil system is not bled at all or bled insufficiently, the bearings of the engine will not get enough luication, which in turn may result in engine failure. Therefore, we recommend that you have the engine oil changed by your authorized KTM mechanic. During the guaranty period, the oil change must be performed by an authorized KTM mechanic. Otherwise, the guarantee will become void. The engine oil change is to be carried out when the engine is still warm. AN ENGINE HAVING BEEN RUN WARM, AND THE ENGINE OIL IN IT IS VERY HOT - DO NOT BURN YOURSELF. 5 6 Place the motorcycle on a horizontal surface. Remove the two plugs [3] and [4], and drain oil into a container. PLUG [A] MUST NOT BE REMOVED, THIS IS PART OF THE BY-PASS VALVE. Remove the screws and the cover [5]. Loosen the fine screen filter [6] with an oil filter wrench and then screw it off by hand. 8 7 The screw [6] must be removed to allow the motor oil to flow out of the frame east pipe. Clean the plugs thoroughly with petroleum and compressed air in order to remove any metal filings. After the oil has drained completely, clean the sealing areas and remount the plugs together with their gaskets. Tighten plug [3] with 30 Nm and plug [4] with 0 Nm. Tighten the screw [6] with 0 Nm. Clean sealing surfaces on the frame east pipe [7], fill new fine screen filter with engine oil, and oil rubber gasket [8]. Replace fine screen filter and screw it back in place, your bare hand will do. Remove oil dipstick on the clutch cover, fill with.3 litre (0.34 US gallons) engine oil and attach plug again USE ONLY ORIGINAL KTM FINE SCREEN FILTERS. USING ANOTHER FILTER BRAND CAN RESULT IN DAMAGE TO THE ENGINE. IF THE ENGINE OIL HAS BEEN DRAINED FROM THE FRONT PIPE OF THE FRAME, YOU MUST BLEED THE OIL SYSTEM! To facilitate bleeding of the oil system, we have added a hose connection piece and a plastic hose to the set of tools. Take an empty oil can ( liter) and drill a 7 mm (0.8 in) -diameter hole into the lid. Screw the hose connection piece into the lid from the outside, and secure it from the inside with the M8 hexagon nut. Slip the plastic hose onto the hose connection piece, and you will have your filling tool.

45 MAINTENANCE WORK ON CHASSIS AND ENGINE» A Fill 0.6 liters (0.6 US gallons) of engine oil into the can and remove the plug [] next to the steering head. Introduce the plastic hose into the vent hole [A], (see page 30) and fill 0.6 liters (0.6 US gallons) of engine oil into the frame s front tube. Remove plastic hose, start engine, and let it idle (approx. 0 seconds) until oil escapes at the hole [A]. As soon as oil begins to leak out, switch off the engine, mount the plug and gasket and tighten to 5 Nm. Let the motor run until it warms. Check the oil drain plugs and the fine screen filter to make sure they are properly sealed. Check the level of the motor oil. Place the motorcycle on a horizontal surface (main stand) and wait for 5 minutes.checking the oil level, he should be between the two marks on the inspection glass, however, it must never rise above the MAX mark. Otherwise, engine oil would get into the air filter box by way of the engine venting system. Add engine oil, if necessary INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE. CHECKING THE ENGINE OIL LEVEL WHEN THE ENGINE IS COLD RESULTS IN A FALSE READING ON THE OIL DIPSTICK AND THEREFORE AN INCORRECT OIL LEVEL. DO NOT OVERFILL THE ENGINE CASE. DO NOT UNDERFILL THE ENGINE CASE. Afterwards check the entire oil system and motor to make sure they are properly sealed. Attach the covering of the fine screen filter to the frame east pipe. Note: Dispose of used oil properly! Under no circumstances may used oil be disposed of in the sewage system or in the open countryside. liter (0.64 US gallons) oil contaminates liter ( US gallons) water. Changing oil filter * Replace the oil filter when changing the engine oil. Press the foot ake pedal and place a screwdriver or similar between foot ake pedal and stopper roll so that the oil filter cover is more accessible. Remove banjo bolt [] and the three screws. Remove oil filter cover [3] and oil filter. Clean the filter case, oil filter cover and sealing areas. Make sure the oil duct in the oil filter cover is not clogged. Place the new oil filter [4] on the connection in the oil filter cover and mount together with a new seal [5]. Tighten the 3 screws in the filter cover to 5 Nm. Tighten the hollow screw with seals and tighten to 5 Nm. Finally, start the engine and check the oil system for leakage